Fuel Tank: Service and Repair

FUEL TANK




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. Carry out steps 2 to 6 of REMOVAL in FUEL LEVEL SENSOR UNIT, FUEL FILTER, AND FUEL PUMP ASSEMBLY on main and sub fuel level sensor units. Refer to "Fuel Pump; Service and Repair; Removal and Installation".
2. Remove the exhaust front tube, center 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
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 of the filler hose so that the remaining length for tightening becomes 8 to12 mm (0.31 to 0.47 in) fuel tank side and 5.7 to 9.7mm (0.224 to 0.382 in) fuel filler tube side.
- 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 switch 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.