Fuel Tank Removal and Installation

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.




1. Complete the "BEFORE REPAIR PROCEDURE".
2. Disconnect the negative battery cable.
3. Siphon the fuel from the fuel tank.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Complete the "AFTER REPAIR PROCEDURE".

Fuel Drawing Note
1. Remove the fuel-filler cap and insert a hose into the fuel tank through the fuel-filler pipe.
2. Siphon the fuel into a container by using a fuel drawing pump.

NOTE: For easier work, prepare a hose of following size.




Specification
Outer diameter: 13 mm {0.51 in}
Length: 2160 mm {85.0 in} or longer

Fuel Pipe Disassembly Note
Piping side

1. Inspect that the fuel pipe joint area is free of foreign material. Clean if necessary.




2. Squeeze the tabs of the retainer and disconnect the fuel pipe connector.




3. Cover the disconnected connector and pipe to prevent them from scratched or contaminated with foreign material.

CAUTION: Removing the retainer from the disconnected pipe will reduce the effectiveness of the retainer. The retainer must be replaced when any of the followings applies.
1. Retainer has been removed.
2. Scratches or damage observed on the retainer.
3. Fuel pump assembly has been replaced.
4. Fuel pipe has been replaced.

4. If removal of the retainer is required, remove it in the following procedure.

CAUTION: Removing the retainer by using a tool can damage the pipe and cause fuel leakage. Remove the retainer by opening the tabs outward by hand.

1. Open the tabs of the retainer outward.




2. Remove and discard the retainer.

Fuel pump side

CAUTION: The retainer must be replaced If removed from the fuel pipe without using the SST. Otherwise, effectiveness of the retainer will be reduced.

1. Inspect that the quick release connector joint area is tree of foreign materials. Clean as necessary.




2. Set the SST as shown and push into the quick release connector to disconnect the plastic fuel hose.




3. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign materials.




Nonreturn Valve Installation Note
- Align the nonreturn valve with the notch in the fuel filler pipe as shown, then install.

Fuel Pipe Assembly Note
Piping side
1. When retainer is not removed, observe the following procedure.
1. Inspect the fuel pipe for kinks. Replace the fuel pipe if necessary.
2. Inspect that the inside of the pipe and the connector is free of foreign material and damage. Clean if necessary, taking care not to damage the sealing surfaces.




3. Align the pipe and connector so that the tabs of the retainer are correctly fitted into the connector. Push the connector into the retainer until two clicks are heard.
4. Pull the connector by hand and verify that it is installed securely. Visually check that the tabs of the retainer are securely fitted into the connector.

2. When retainer is removed, observe the following procedure.

NOTE: Use the designated genuine retainer only.

1. Install a new retainer onto the connector.
2. Inspect that the inside of the pipe and the connector is free of foreign material and damage. Clean if necessary, taking care not to damage the sealing surfaces.




3. Push the connector into the retainer until a click is heard.
4. Pull the connector by hand and verify that it is installed securely. Visually check that the tabs of the retainer are securely fitted into the connector.

Fuel pump side
1. Inspect that the inside of the fuel pipe and the quick release connector is free of forcing materials and damage. Clean as necessary, taking care not to damage the sealing surfaces.




2. Push the quick release connector into the fuel pipe until a click is head.
3. Pull the quick release connector by hand and verify that it is installed securely.

Evaporative Hose Installation Note
- Fit each hose onto the pipe over 25 mm {0.98 in}.

Joint Hose Installation Note
- Fit the joint hose onto the pipe over 35 mm {1.38 in}.




- Install clamps as shown.