Fuel Tank: Service and Repair

FUEL TANK REMOVAL/INSTALLATION [L3 WITH TC]

WARNING:
- Repairing a fuel tank that has not been properly steam-cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.
- A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

CAUTION:
- Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Level the vehicle.

2. Complete the "BEFORE SERVICE PRECAUTION". (See Before Service Precaution.)

3. Disconnect the negative battery cable.

4. Remove the rear seat cushion.

5. Remove the fuel pump unit. (See Fuel Pump Unit Removal/Installation.)

6. Remove the fuel gauge sender unit.

7. Siphon the fuel from the fuel tank.

8. Remove the middle pipe. (See Service and Repair.)

9. Remove the propeller shaft. (4WD) (See Service and Repair.)

10. Remove the rear under cover (LR, RR).

11. Remove the rear parking brake cable installation bolts, then move the rear parking brake cable out of the way.

12. Disconnect the joint hose connected between the fuel tank and the fuel-filler pipe from the fuel-filler pipe.

13. Disconnect the breather hose connected between the fuel tank and the fuel-filler pipe from the fuel-filler pipe.

14. Disconnect the evaporative hose connected between the fuel tank and the charcoal canister from the charcoal canister.

15. Remove in the order indicated in the table.










16. Install in the reverse order of removal.

17. Complete the "AFTER SERVICE PRECAUTION". (See After Service Precaution.)

Rivet Removal Note

CAUTION:
- Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.

NOTE:
- The insulator is installed using rivets.
- When resin stalling the rivet, install the same rivet or M5 bolt and nut.

1. Push out the mandrel using a hammer and punch (2-2.8 mm {0.08-0.11 in} diameter).






2. Remove the flange using a drill (5 mm {0.20 in} drill bit).






Fuel-filler Pipe Removal Note

1. Remove the rear tire (LH).

2. Remove the mudguard (LH).

3. Remove the air filter.

4. Remove the fuel-filler pipe.

Joint Hose Installation Note

1. Install the joint hose and clamp as shown in the figure.






Breather Hose Installation Note

1. Install the breather hose and clamp as shown in the figure.