Fuel Tank Removal and Installation
FUEL TANK REMOVAL/INSTALLATIONWARNING: 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. (See Fuel Drawing Note.)
4. Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove the propeller shaft.
6. Remove the power plant frame. (See MANUAL TRANSMISSION REMOVAL/INSTALLATION [M15M-D].) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION.)
7. Remove in the order indicated below.
1. Parking brake cable.
2. Brake pipe (See AIR BLEEDING)
3. Shock absorber bolt
4. Rear crossmember component (See Rear Crossmember Component Removal Note)
5. Charcoal canister
6. Fuel tank insulator
7. Service hole cover
8. Connector
9. Plastic fuel hose
(See Plastic Fuel Hose Disassembly Note)
(See Plastic Fuel Hose Assembly Note)
10. Evaporative hose (See Breather Hose, Evaporative Hose Installation Note)
11. Joint hose (See Joint Hose Installation Note)
12. Breather hose (See Breather Hose, Evaporative Hose Installation Note)
13. Dust cover
14. Fuel-filler pipe
15. Fuel-filler cap
16. Fuel tank
8. Install in the reverse order of removal.
9. 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 using a fuel drawing pump.
NOTE: For ease of work, prepare a hose of following size.
Specification
Outer diameter: 13 mm {0.51 in}
Length: 2160 mm {85.0 in} or longer
Rear Crossmember Component Removal Note
1. Support the rear crossmember component using a transmission jack.
2. Remove the rear crossmember mounting bolts and nuts.
3. Lower the rear crossmember component.
Plastic Fuel Hose Disassembly Note
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 free of foreign material.
2. Clean if necessary.
3. Set the SST as shown and push it into the quick release connector to disconnect the plastic fuel hose.
4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.
Breather Hose, Evaporative Hose Installation Note
1. Fit each hose onto the respective fittings within specification, and install clamps as shown.
Joint Hose Installation Note
1. Fit the joint hose onto the respective fittings within specification, and install clamps as shown.
Plastic Fuel Hose Assembly Note
1. Verify that the inside of the fuel pipe and the quick release connector is free of foreign material and damage.
2. Clean if necessary, taking care not to damage the sealing surfaces.
3. Push the quick release connector into the fuel pipe until a click is heard.
4. Pull the quick release connector by hand and verify that it is installed securely.