Removal and Replacement

Fuel Tank

Removal

WARNING:
^ After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.
^ Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
^ Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
^ If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical attention.
^ This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
^ Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.

CAUTION: Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

1. Position the vehicle on a lift.
2. Disconnect the battery ground cable.

WARNING: The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

3. Drain the fuel tank.
4. Remove the RH fuel tank access cover.
^ Remove the 4 nuts.

CAUTION: Under no circumstance should the ignition switch be in the ON position, during the disconnection of the fuel pump electrical connector.

5. Disconnect the fuel pump electrical connector.
6. Remove the rear driveshaft.
7. Remove the RH rear fender splash shield.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

8. Release the fuel tank breather hose from the fuel tank filler pipe.
^ Remove and discard the hose clip.
^ Install blanking caps to the exposed ports.

9. Remove the joining clip from the fuel tank breather hose and the vent hose.
10. Release the fuel tank breather hose and the vent hose from the securing clip.
11. Remove the fuel tank shields.
^ Remove the 14 bolts.
^ Remove the 4 nuts.

CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

13. Disconnect the 2 fuel lines.
^ Position a container to collect the fuel spillage.
^ Disconnect the 2 quick release connectors.
^ Install blanking caps to the exposed ports.

CAUTION: Position the breather hose and vent hose through the vehicle body during the fuel tank removal operation.

14. With assistance, remove the fuel tank.
^ Remove the 5 bolts.

CAUTION: Before disconnecting or removing the components, make sure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

NOTE: Do not disassemble further if the component is removed for access only.

15. Remove the fuel tank breather hose and vent hose from the fuel tank.
^ Remove the two clips.

16. Remove the fuel tank support straps from the fuel tank.
^ Remove the 4 clips.

Installation
1. Install the fuel tank support straps to the fuel tank.
^ Secure with the clips.

2. Install the fuel tank breather hose and vent hose to the fuel tank.
^ Secure with the clips.

3. Position fuel tank with the fuel tank breather hose and vent hose to the vehicle.

CAUTION: Position the breather hose and vent hose through the vehicle body during the fuel tank installation operation.

4. With assistance, install the fuel tank.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).

5. Connect the fuel lines.
^ Connect the quick release connectors.

6. Install the fuel tank filler pipe to the fuel tank filler hose.
^ Tighten the clip.

7. Install the fuel tank shields.
^ Tighten the nuts and bolts to 25 Nm (18 ft. lbs.).

8. Install the fuel tank breather hose and vent hose to the fuel tank filler pipe.
^ Install the clips.

9. Install the RH rear fender splash shield.
10. Install the rear driveshaft.
11. Connect the fuel pump electrical connector.
12. Install the RH fuel tank access cover.
13. Fill the fuel tank with the amount recovered during the fuel tank drain procedure.
14. Connect the battery ground cable.