Fuel Tank: Service and Repair

FUEL TANK

Exploded View

FL-10 Exploded View:

Removal and Installation

WARNING: Be sure to read "General Precautions" when working on the fuel system. Refer to FL-2, "General Precautions". Service Precautions

REMOVAL
- 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 exhaust front tube, center muffler and main muffler.
3. Remove propeller shaft.
4. Remove parking rear brake cables.
5. Remove rear suspension member assembly.




6. Disconnect fuel filler hose (1), EVAP tube (2) and vent hoses (3) at fuel tank side.
- To disconnect quick connector.

7. Remove fuel tank protector.




8. Support the lower part of fuel tank (1) with transmission jack (A).

CAUTION: Support the position that fuel tank mounting bands never engage.

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

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

11. Remove fuel filler tube, as 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 the clamp hand with the top mark (A) until the mark is on the bolt head flange.
- To connect quick connector.

Inspection

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leakage.

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 check there are no fuel leakage at the fuel system tube and hose connections.
- After removing/installing rear suspension assembly, check to adjust wheel alignment. Refer to RSU-6, "Inspection".