Fuel Tank: Service and Repair

Removal And Installation:

REMOVAL

WARNING: Read "Service Precautions" before working on the fuel system.

1. Drain fuel from fuel tank if necessary.
- Perform work on level place.
2. Perform steps 2 to 7 of "REMOVAL" in "FUEL LEVEL SENSOR UNIT", "FUEL FILTER AND FUEL PUMP ASSEMBLY" on main and sub fuel level sensor units. Refer to "REMOVAL".
3. Remove the exhaust front tube, center muffler and main muffler. Refer to "Removal and Installation".
4. Remove insulator.
5. Remove propeller shaft. Refer to "REAR PROPELLER SHAFT".
6. Remove parking brake cables. Refer to "PARKING BRAKE CONTROL".
7. Remove rear suspension assembly. Refer to "REAR SUSPENSION ASSEMBLY".
8. Remove fuel tank protector.




9. Disconnect fuel filler hose, vent hose and EVAP hoses at fuel tank side.




10. Remove fuel tank mounting band bolts while supporting fuel tank.
11. Remove the fuel tank.

INSTALLATION
Install in the reverse order of removal paying attention to the following.
- Surely clamp fuel hoses and insert hose to the length below.

Fuel filler hose : 35 mm (1.38 in)
The other hoses : 25 mm (0.98 in)

- Be sure hose clamp is not placed on swelled area of fuel tube.
- Tighten each clamp of the filler hose so that the remaining
length for tightening becomes 8 to 12 mm (0.31 to 0.47 in) on fuel tank side and 5.7 to 9.7 mm (0.224 to 0.382 in) on fuel filler tube side.
- To connect the quick connector, refer to "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY".

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch ON (do not start engine), and check connections for leakage by applying fuel pressure to fuel piping.
2. Start the engine and rev it up and check for fuel leaks at the fuel system tube and hose connections.
- After removing/installing rear suspension assembly, make sure to adjust wheel alignment and then, adjust neutral position of steering angle sensor.