Fuel Tank: Service and Repair

WARNING: WHEN REPLACING FUEL LINE PARTS, BE SURE TO OBSERVE THE FOLLOWING:
- PUT A "CAUTION: INFLAMMABLE" SIGN IN WORKSHOP.
- DO NOT SMOKE WHILE SERVICING FUEL SYSTEM. KEEP OPEN FLAMES AND SPARKS AWAY FROM WORK AREA.
- BE SURE TO FURNISH THE WORKSHOP WITH A CO2 FIRE EXTINGUISHER.
- PUT DRAINED FUEL IN AN EXPLOSION-PROOF CONTAINER SECURE THE LID.

REMOVAL AND INSTALLATION
1. Release fuel pressure from fuel line and disconnect battery ground cable.





2. Remove inspection hole cover located behind the rear seat.
3. Disconnect harness connectors under inspection hole cover.





4. Disconnect fuel tubes located on the lower RH side of the fuel tank and put mating marks on the tubes for correct installation.
5. Remove the exhaust center tube, propeller shaft, differential carrier, rear suspension member and drive shafts.





6. Disconnect filler hose at fuel tank side and vent hose at filler tube side.
7. Remove fuel tank protector.
8. Remove fuel tank band mounting bolts while supporting fuel tank.
9. Remove fuel tank.
10. Reverse procedure to install, noting the following:





11. When installing filler collar, place the protrusion of the collar flange upward.





12. When installing the grommet of the filler tube, align the protrusion on the grommet with the notch on the filler tube.





13. When installing the inspection hole, put the arrow mark forward.

NOTES:
- Always replace O-ring with new ones.
- Do not kink or twist hose and tube when they are installed.
- Do not tighten hose clamps excessively to avoid damaging hoses.
- When installing fuel check valve, be careful of its designated direction.
- After installation, run engine and check for fuel leaks at connections.