Removal and Replacement
Fuel Tank Removal and InstallationWARNING: When performing the following procedure, be sure to observe Precautions on Fuel System Service in order to reduce the risk of fire and personal injury.
Removal
1. Relieve fuel pressure in fuel feed line.
2. Disconnect negative cable from battery.
3. Remove fuel filler cap.
4. Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel in space "A" as shown in figure.
CAUTION: Do not force pump hose into fuel tank, or pump hose may damage of fuel tank inlet valve (2).
CAUTION: Do not force pump hose into fuel tank, or pump hose may damage of fuel tank inlet valve (2).
5. Remove propeller shaft.
6. Remove exhaust center pipe.
7. With parking brake cable connected, remove parking brake cable bolt and nut.
8. Remove rear fender lining.
9. Remove breather hose (1) from fuel filler neck.
10. Remove clamps (2) and fuel filler hose (1) from fuel filler neck.
11. Remove fuel pump wire connector (3), and remove clamp (4) from bracket.
12. Drain fuel from fuel tank.
CAUTION: Never store fuel in an open container due to possibility of fire or explosion.
13. Disconnect quick joints (1) from fuel pipes (2).
14. Support fuel tank (1) with jack (2) and remove fuel tank.
Installation
CAUTION: When connecting joint, clean outside surfaces of pipe where joint is to be connected, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.
1. Raise fuel tank (1) with jack (2) and install fuel tank to vehicle.
Tightening torque
Fuel tank bolt (a): 45 N.m (4.6 kg-m, 33.5 lbf-ft)
2. Connect fuel feed hose (1) and vapor hose (2) to each pipe as shown in figure.
3. Connect fuel pump wire connector (3), and install fuel pump wire to bracket (2).
4. Connect fuel filler hose (1) to filler neck (3) as shown in figure, and tighten fuel filler hose clamp to specified torque.
Tightening torque
Fuel filler hose clamp (a): 1.5 N.m (0.15 kg-m, 1.5 lbf-ft)
5. Connect breather hose (1).
6. Install rear fender lining.
7. Install parking brake cable bolt and nut.
8. Install exhaust center pipe.
9. Install propeller shaft.
10. Connect negative cable to battery.
11. Check fuel leaks.