Fuel Tank: Service and Repair

Removal and Installation

REMOVAL

WARNING: Read "Service Precautions" before working on the fuel system.

- Drain fuel from fuel tank if necessary.
- Perform work on level place.

1. On main and sub fuel level sensor unit carry out steps 2 to 7 of "REMOVAL" in "FUEL LEVEL SENSOR UNIT, FUEL FILTER, AND FUEL PUMP ASSEMBLY". Refer to "Fuel Pump; Service and Repair; Removal and Installation".
2. Remove the exhaust front tube, center muffler and main muffler.
3. Remove propeller shaft.
4. Remove parking brake cables.
5. Remove rear suspension assembly.
6. Remove fuel tank protector.




7. Disconnect fuel filler hose vent hose and EVAP hoses at fuel tank side.




8. Remove fuel tank mounting band bolts while supporting fuel tank.
9. Remove the fuel tank.

INSTALLATION
1. Install in the reverse order of removal paying attention to the following.
- Surely clamp fuel hoses and insert hose to the length below.

Fuel filler hose: 35 mm (1.38 in)
The other hoses: 25 mm (0.98 in)

- Be sure hose clamp is not placed on swelled area of fuel tube.
- Tighten each clamp (both ends) of the filler hose so that the remaining length for tightening becomes 8 to 12 mm (0.31- 0.47 in).
- To connect the quick connector, refer to "Fuel Pump; Service and Repair; Removal and Installation".

INSPECTION AFTER INSTALLATION
- Use the following procedure to check for fuel leaks.
1. Turn ignition key ON (do not start engine) and check connections for leakage by applying fuel pressure to fuel piping.
2. Run the engine and check for fuel leaks at the fuel system tube and hose connections.