Fuel Tank: Service and Repair

Removal
1. Relieve fuel pressure in fuel feed line according to procedure.
2. Disconnect negative cable at battery.





3. Remove rear seat cushion, rear right seat back, right side sill scuff, right front partition trim and right rear door opening trim.
4. Disconnect fuel pump and fuel level gauge wire at coupler.
5. Hoist vehicle.





6. Remove muffler.





7. Disconnect fuel filler hose and breather hose from filler neck.
8. As fuel tank has no drain plug, drain fuel tank by pumping fuel not through fuel tank filler. Use hand operated pump device to drain fuel tank.

CAUTION: Never drain or store fuel in an open container to avoid possibility of fire or explosion.





9. Disconnect fuel hoses from pipes.

WARNING: A small amount of fuel may be released after the fuel hose is disconnected. In order reduce the chance of personal injury, cover the hose and pipe to be disconnected with a shop cloth. Be sure to put that cloth in an approved container when disconnection is completed.

10. Remove fuel tank from vehicle.

Installation





1. Install fuel pump and fuel level gauge to fuel tank. Use new gaskets.
2. Connect fuel hoses and pipes to fuel tank. Clamp hoses and wire harness securely.
3. Connect fuel breather hose to fuel tank.
4. Install fuel tank to vehicle.





5. Connect fuel filler hose to tank and breather hose to filler neck as shown in figure and clamp them securely.





6. Connect fuel and vapor hoses to pipes as shown in figure and clamp them securely.





7. Install muffler and tighten nut to specified torque.

Tightening Torque: (a): 50 Nm (36.5 lb ft)





8. Connect fuel pump and level gauge coupler and install grommet securely.
9. Install right rear door opening trim, right front partition trim, right side sill scuff, rear seat back and rear seat cushion.
10. Connect negative cable at battery.
11. With engine "OFF" and ignition switch "ON", check for fuel leaks.
12. Start engine and check each joint of exhaust system for leakage.