Fuel Tank Removal and Installation

Fuel Tank Removal and Installation

Removal

1) Relieve fuel pressure in fuel feed line. Service and Repair
2) Disconnect negative (-) cable from battery.
3) Hoist vehicle.
4) Remove exhaust center pipe. Exhaust System Components
5) Remove rear propeller shaft. Propeller Shaft Removal and Installation
6) With cable connected, detach parking brake cable clamp from fuel tank cover. Locations
7) Disconnect fuel filler hose (2) from fuel filler neck referring to Step 1) to Step 3) of "Removal" under Fuel Tank Inlet Valve Removal and Installation Fuel Tank Inlet Valve Removal and Installation.
8) Disconnect fuel pump connector (1).





9) Drain fuel from fuel tank.

WARNING:
There is a risk of fire or explosion if the drained fuel is stored in an inappropriate container.

Avoid using an open container to hold the fuel.

NOTE:
The hose of the hand-operated pump could damage the fuel tank inlet valve if too much force is used when inserting it into the fuel tank.

Do not apply too strong a force when inserting the pump hose into the fuel tank.

10) Disconnect fuel feed pipe (2) and EVAP canister hose (1) from each pipe. Fuel Hose Disconnecting and Reconnecting





11) Remove fuel tank cover (1).





12) Support fuel tank (1) with jack (2) and remove fuel tank bolts.





13) Disconnect breather hose (1) from fuel tank while lowering fuel tank, and remove fuel tank.






Installation

Fuel Tank Inspection

Fuel Tank Purging Procedure

WARNING:

Failure to take proper precautions when reinstalling the fuel tank connections can result in fuel leakage or damage.

Clean the outside surface of the pipe where each quick joint is to be installed, push the pipe into the joint until the joint lock clicks, and then confirm that the pipe is connected securely.

1) If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack (2), and connect breather hose to fuel tank.
3) Install fuel tank to vehicle.

Tightening torque
Fuel tank bolt (a): 45 Nm (4.6 kgf-m, 33.5 lbf-ft)





4) Install fuel tank cover.
5) Connect fuel filler hose (1) to fuel tank as shown in figure, and clamp them securely. Fuel Hose Disconnecting and Reconnecting

Tightening torque
Fuel filler hose clamp (a): 3.5 Nm (0.36 kgf-m, 3.0 lbf-ft)

6) Connect fuel pump connector (2).





7) Connect fuel feed pipe (2) and EVAP canister hose (1) to each pipe as shown in figure, and clamp them securely. Fuel Hose Disconnecting and Reconnecting






8) Install parking brake cable clamp to fuel tank cover. Locations
9) Install rear propeller shaft. Propeller Shaft Removal and Installation
10) Install exhaust center pipe. Exhaust System Components
11) Connect negative (-) cable to battery.
12) With engine stationary, turn ignition switch to ON position and check for fuel leaks. Fuel Leakage Check Procedure