Fuel Tank: Service and Repair

FUEL TANK




Removal and Installation

REMOVAL

WARNING: Be sure to read "General Precautions" when working on the fuel system. Refer to "General Precautions".
- Drain fuel from fuel tank if necessary.
- Perform work on level place.

1. 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.
2. Remove tunnel stay. Refer to "REAR SUSPENSION ASSEMBLY".
3. Remove exhaust front tube, center muffler and main muffler. Refer to "EXHAUST SYSTEM".
4. Remove insulator.
5. Remove propeller shaft. Refer to "REAR PROPELLER SHAFT".
6. Remove parking rear 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. Support the lower part of fuel tank with transmission jack.






CAUTION: Support the position that fuel tank mounting bands do not engage.

11. Remove fuel tank mounting bands.
12. Supporting with hands, descend transmission jack carefully, and remove fuel tank.

CAUTION:
- Make sure that all connection points have been disconnected.
- Confirm there is no interference with vehicle.

13. Remove fuel filler tube protector and fuel filler tube, if necessary.

INSTALLATION
Note the following, and install in the reverse order of removal.
- 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 fuel hose clamp so that the distance between its lugs becomes to the following.

Fuel tank side : 8 - 12 mm (0.31 - 0.47 in)
Fuel filler tube side : 5.7 - 9.7 mm (0.224 - 0.382 in)

- To connect quick connector, refer to "Quick Connector".

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch "ON" (with engine stopped), and check connections for leakage by applying fuel pressure to fuel piping.
2. Start engine and rev it up and make sure there are no 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. Refer to "Wheel Alignment Inspection" and "Adjustment of Steering Angle Sensor Neutral Position".