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.





4. Disconnect fuel level gauge, fuel pump and fuel tank pressure sensor connector (if equipped) lead wire couplers.
5. Hoist vehicle.





6. Disconnect fuel filler hose and breather hose from filler neck.
7. 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.





8. 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.

9. Remove fuel tank from vehicle.

FUEL TANK PURGING PROCEDURE

WARNING: This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank using heat or flame as an explosion resulting in personal injury could occur.

Following procedure is used for purging fuel tank.
1. After removing fuel tank, remove all hoses, pipes, fuel cut valves, fuel pump and fuel level gauge from fuel tank.
2. Drain all remaining fuel from tank.
3. Move tank to flushing area.
4. Fill tank with warm water or tap water, and agitate vigorously and drain. Repeat this washing until inside of tank is clean. Replace tank if its inside is rusty.
5. Completely flush out remaining water after washing.

CAUTION: Never remain water in fuel tank after washing, or fuel tank inside will get corrosion.





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 and clamp them securely.





6. Connect fuel hoses to filter and pipes as shown and clamp them securely.





7. Connect fuel pump, level gauge couplers and fuel tank pressure sensor connector (if equipped). Fix its wire with tape as shown.
8. Install rear seat cushion.
9. Connect negative cable to battery.
10. With engine "OFF" and ignition switch "ON", check for fuel leaks.