Fuel Tank: Service and Repair
FUEL TANK ASSEMBLYWarning:
- Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage Always keep sparks and flames away from fuel.
- Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures".
- 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.
Removal / Inspection / Installation
1. Disconnect the negative battery cable.
2. Remove the rear seat cushion.
3. Disconnect the fuel pump connector.
4. Suck up the fuel from the fuel tank, referring to Removal note.
5. Remove in the order shown in the figure.
6. Inspect all parts and repair or replace as necessary.
7. Install in the reverse order of removal.
1. Fuel pump cover
2. Fuel pump connector
3. Fuel hose
4. Fuel filler hose
5. Breather hose
6. Fuel tank strap
7. Fuel tank
8. Fuel filler cap
9. Reinforcement
10. Fuel filler pipe
Removal note
Fuel
1. Remove the filler cap and insert a hose into the fuel tank through the filler pipe.
2. Start the pump and suck up the fuel into a container.
Note: For easier work, prepare a hose of following size.
Outer diameter: 13 mm (0.51 in)
Length: 2,160 mm (85.O in)
Fuel Tank Caution
The fuel tank is divided into the right and left banks which makes it difficult to suck up the fuel completely. Some fuel may be left in either side of the tank. Avoid tilting the fuel tank during removal.
Disassembly / Assembly
1. Remove the fuel tank.
2. Disassemble in the order shown in the figure, referring to Disassembly / Assembly note.
3. Assemble in the reverse order of disassembly, referring to Disassembly / Assembly note.
1. Fuel filter (high-pressure side)
2. Harness
3. Union nut
4. Fuel pump assembly
5. Fuel gauge sender unit No.1
6. Fuel gauge sender unit No.2
7. Fuel filter (transfer)
8. Check valve (two-way)
9. Check valve (one-way)
10. Fuel vapor valve
Special Service Tool (SST) 49T042 001:
Disassembly / Assembly note
Fuel pump assembly
Disassemble / assemble the fuel pump assembly by using the SST.
Tightening torque: 94-102 N-m (9.5-10.5 kg-m, 69-75 ft-lb)