Fuel Tank: Service and Repair

FUEL TANK




Removal and Installation

REMOVAL

WARNING:
Read General Precautions before working on the fuel system. Refer to "General Precautions".
- Drain fuel from fuel tank if necessary.
- Perform work on level place.

1. Carry out steps 2 to 7 of REMOVAL in FUEL LEVEL SENSOR UNIT, FUEL FILTER, AND FUEL PUMP ASSEMBLY on main and sub fuel level sensor units. Refer to "REMOVAL".
2. Remove and tunnel stay. Refer to "Suspension / Diagrams".
3. Remove the exhaust front tube, center muffler.
4. Remove propeller shaft.

CAUTION: Do not impact or damage propeller shaft tube.

5. Remove parking brake cables.
6. Remove rear suspension assembly.
7. Remove fuel tank protector.




8. Disconnect fuel filler hose, vent hose and EVAP hoses at fuel tank side.




9. Remove fuel tank mounting band bolts while supporting fuel tank.
10. Remove the fuel tank.

INSTALLATION
Install in the reverse order of removal paying attention to the following.
- Surely clamp fuel hoses and insert hose to the length below.
Fuel filler hose : 35 mm (1.38 in)
The other hoses : 25 mm (0.98 in)
- Be sure hose clamp is not placed on swelled area of fuel tube.
- Tighten each clamp (both ends) of the filler hose so that the remaining length for tightening becomes 8 to 12 mm (0.31 to 0.47 in).
- To connect the quick connector, refer to "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY".

INSPECTION AFTER INSTALLATION
- Use the following procedure to check for fuel leaks.
1. Turn ignition switch ON (do not start engine), and check connections for leakage by applying fuel pressure to fuel piping.
2. Run the engine and check for fuel leaks at the fuel system tube and hose connections.