Removal and Replacement

Fuel Tank

REMOVAL

WARNING: Place "NO FIRE" signs near the working area.

CAUTION: Be careful not to spill fuel.

1. Set the vehicle on a lift.
2. Release the fuel pressure.
3. Disconnect the ground cable from the battery.
4. Drain fuel from fuel tank.
5. Remove the second seat.
6. Remove the service hole cover of fuel pump.
1. Disconnect the connector (C).
2. Remove the bolt (A).
3. Push the grommet (B) down and remove service hole cover.






7. Remove the service hole cover of fuel sub level sensor.







8. Disconnect the quick connector on the fuel delivery hose.






9. Remove the rear wheels.
10. Lift up the vehicle.
11. Remove the clip holding the harness.






12. Remove the rear suspension assembly.
13. Disconnect evaporation hose (A), connector (B) and fuel filler hose (C).






14. Remove the fuel tank from the vehicle.

WARNING: A helper is required to perform this work.

1. Support the fuel tank with the transmission jack.
2. Remove the fuel tank band that holds the fuel tank.
3. Remove the fuel tank from the vehicle.






INSTALLATION

1. Install the fuel tank to the vehicle.

WARNING: A helper is required to perform this work.


1. Lift the fuel tank with the transmission jack.
2. Mount the fuel tank to the vehicle with a jack.
3. Install the fuel tank band that holds the fuel tank.

Tightening torque: 33 N.m (3.4 kgf.m, 24.3 ft.lb)






2. Connect evaporation hose (A), connector (B) and fuel filler hose (C).






3. Install the rear suspension assembly.
4. Install the clip that holds the harness.






5. Lower the vehicle.
6. Install the rear wheels.

Tightening torque:
Chrome plated wheel: 150 N.m (15.3 kgf.m, 110.6 ft.lb)
Other than above: 120 N.m (12.2 kgf.m, 88.5 ft.lb)

7. Connect the quick connector on fuel delivery hose.
8. Install the service hole cover of fuel sub level sensor.






9. Install the service hole cover of fuel pump.
1. Push on the grommet (B) to install it to the service hole cover.
2. Tighten the bolt (A).
3. Connect the connector (C).






10. Install the second seat.
11. Install the fuse of fuel pump to the main fuse box.
12. Connect the battery ground cable to the battery.