Fuel Tank: Service and Repair

FUEL TANK

Component

FL-10 Component:

Removal and Installation

REMOVAL

WARNING: Be sure to read "General Precautions" when working on the fuel system. Refer to FL-3, "General Precaution". Technician Safety Information

- 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 RSU-5, "On-Vehicle Inspection and Service".
3. Remove exhaust front tube, center muffler and main muffler.
4. Remove insulator.
5. Remove propeller shaft. Refer to PR-7, "On-Vehicle Inspection".
6. Remove parking rear brake cables.
7. Compress coil spring and remove coil spring.
8. Remove rear suspension assembly.
9. Remove fuel tank protector.




10. Disconnect fuel filler hose, vent hose and EVAP hoses at fuel tank side.
11. Support the lower part of fuel tank with transmission jack.






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

12. Remove fuel tank mounting bands.
13. 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.

14. 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)

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.