Fuel Tank: Service and Repair

Fuel Tank Removal and Installation

Removal

WARNING: The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

1. Relieve the fuel pressure. Refer to Fuel System Pressure Release.
2. Disconnect the negative battery cable.
3. Drain the fuel tank.




4. Remove the front muffler. Refer to Muffler - Front Removal and Installation.
5. Remove the fuel tank filler tube clamp at the fuel tank.




6. Disconnect the fuel tank filler tube.




7. Disconnect the fuel line near the right front of the fuel tank.
8. Remove the rear seat. Refer to Rear Seat Cushion Removal and Installation.




9. Remove the fuel pump access cover.
10. Disconnect the electrical connector at the fuel pump assembly.




11. Disconnect the fuel line.
12. Remove the parking brake cables support bracket bolt.




13. Remove the parking brake cables from the fuel tank.




14. Disconnect the fuel vapor line from the solenoid valve.
15. Support the fuel tank.
16. Remove the fuel tank strap retaining nuts.
17. Remove the fuel tank strap.
18. Carefully lower the fuel tank.
19. Remove the fuel tank.




20. Transfer any parts as needed.

Installation
1. Raise the fuel tank into position.
2. Install the fuel tank straps.




3. Install the fuel tank strap retaining nuts.

Tighten: Tighten the fuel tank strap retaining nuts to 20 Nm (15 ft. lbs.).




4. Connect the fuel vapor line from the solenoid valve.
5. Install the parking brake cables support bracket.




6. Install the parking brake cables from the fuel tank.
7. Connect the fuel line.




8. Connect the electrical connector at the fuel pump assembly.
9. Install the fuel pump access cover.




10. Install the rear seat. Refer to Rear Seat Cushion Removal and Installation.




11. Connect the fuel line near the right front of the fuel tank.
12. Connect the fuel tank filler tube.




13. Install the fuel tank filler tube clamp at the fuel tank.
14. Install the front muffler. Refer to Muffler - Front Removal and Installation.
15. Connect the negative battery cable.
16. Fill the fuel tank.




17. Perform a leak check of the fuel tank and the fuel line connections.