Fuel Tank: Service and Repair

Removal Procedure
1. Disconnect the negative battery cable.
2. Remove fuel filler cap.
3. Drain the fuel from fuel filler neck.
4. Disconnect the fuel filler hose at fuel tank.
5. Disconnect the air breather hose at the fuel tank.
6. Disconnect the evaporator hose at the fuel tank.
7. Hold entire fuel tank at the bottom with stands.
8. Disconnect fuel supply lines and fuel return line at near the fuel filter inside of body frame.
9. Remove four bolts (two in front and two in rear) holding fuel tank to the frame.
10. Lower tank assembly from the vehicle a little to make access space on top.
11. Disconnect two electrical connectors at fuel pump.
12. Remove fuel tank assembly from the vehicle.
13. Remove four nuts retaining tank under guard to the tank.
14. Remove the tank from the guard.











Installation Procedure
1. Secure fuel tank into under guard with four retaining bolts, if necessary.
2. Place the fuel tank assembly onto stands.
3. Lift the fuel tank assembly near the position.
4. Connect two electrical connectors at fuel pump.
5. Lift the fuel pump to its position and secure it with four mounting bolts. Make sure that all hoses and fuel lines are out of way between the fuel tank and the fuel tank bracket. Tighten the fuel tank retaining bolts to 36Nm (27 lb ft).
6. Connect fuel supply and return lines.
7. Connect the fuel filler hose, the air breather hose and EVAP hose onto fuel tank and secure them with clamps.
8. Pour fuel into fuel tank.
9. Install fuel filler cap securely.
10. Connect the battery negative cable.