Fuel Tank: Service and Repair

Removal

1. Preparation
(1) Remove the 2nd seat .
(2) Open the carpet for fuel pump (A).




(3) Remove the service cover for fuel pump (A).




(4) Disconnect the fuel pump connector (A).




(5) Start the engine and wait until fuel in fuel line is exhausted.
(6) After engine stops, turn the ignition switch off.
2. Disconnect the fuel tank pressure sensor connector(A) and the fuel feed quick-connector (B).




3. Open the carpet for sub fuel sender (A).




4. Open the service cover for sub fuel sender (A).




5. Disconnect the sub fuel sender connector (A).




6. Lift the vehicle and remove the muffler assembly and the propeller shaft (4WD) .
7. Support the fuel tank with a jack.
8. Disconnect the fuel filler hose (A), the leveling tube quick-connector (B) and the vacuum tube quick-connector (C).




9. Disconnect the vacuum tube quick-connectors (A,B).




10. Unscrew the fuel tank bank mounting nuts (A) and remove the fuel tank from the vehicle.






Installation

1. Install the fuel tank in according to the reverse order of "Removal" procedure.

Fuel tank band mounting nuts:
39.2 - 53.9Nm (4.0 - 5.5kgf-m, 28.9 - 39.8lbf-ft)