Fuel Tank: Service and Repair

REMOVAL
1. Release the fuel pressure.
Refer to FUEL PRESSURE RELEASE.
2. Disconnect the battery ground cable.
3. Open the fuel filler lid and filler cap.
4. Drain the fuel from fuel tank.
5. Remove the rear seat cushion. Refer to Seats; "Removal and Installation".




6. Remove the inspection hole cover located under rear seat.




7. Disconnect the fuel pump electrical connector.




8. Disconnect the fuel feed hose quick connector as follows:
a. Apply mating marks on the fuel pump outlet and the quick connector for installation.
b. Hold the quick connector and push in the tabs, then pull out off of the fuel pump outlet that is inserted into the quick connector.

CAUTION:
- The quick connector can be removed when the tabs are completely depressed. Do not twist the fuel feed hose more than necessary.
- Do not use any tools to remove the quick connector.

9. Remove the center exhaust tube.




10. From rear left area of the fuel tank, remove the filler hose, vent hose, and evaporation hoses as shown.




11. Support the fuel tank with a suitable transmission jack as shown.
12. Remove the fuel tank mounting band bolts while supporting the fuel tank.




13. Lower the fuel tank by 70 - 80 mm (2.76-3.15 in), then remove the nuts and clips holding the fuel tank protector, and remove the protector.
- To remove the clips, use pliers to squeeze the extensions as shown by the arrows, and then remove the clip from above.
14. Remove the fuel tank.

INSTALLATION
Installation is in the reverse order of removal.
Connect the quick connector as follows:




1. Align mating marks on the fuel pump outlet and the quick connector for correct installation.
2. Align the push tabs with the quick connector slots.
3. Insert the fuel pump outlet into the center of the quick connector until you hear a click.

After connecting the quick connector, check that the quick connector is fully seated as follows:




1. Pull on the quick connector to make sure it is firmly connected.
2. Apply fuel pressure to the fuel lines by turning the ignition switch ON (without starting the engine). Then check for fuel leaks at the hose connections.
3. Start the engine and increase engine speed, verify that there are no fuel leaks.