Fuel Tank: Service and Repair

FUEL TANK





Removal and Installation

REMOVAL

WARNING:
Be sure to read "General Precautions" when working on the fuel system. Refer to "General Precautions".

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

1. Perform steps 2 to 7 of "REMOVAL" in "FUEL LEVEL SENSOR UNIT, FUEL FILTER, AND FUEL PUMP ASSEMBLY" on main and sub fuel level sensor units. Removal and Installation
2. Remove exhaust front tube, center muffler and main muffler. Refer to "EXHAUST SYSTEM".
3. Remove insulator then propeller shaft. Refer to "REAR PROPELLER SHAFT" (2WD models) or "REAR PROPELLER SHAFT" (AWD models).
4. Remove parking brake cables. Refer to "PARKING BRAKE CONTROL".
5. Remove rear suspension assembly. Refer to "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
Note to the following, and install in the reverse order of removal.
- 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 clamp (fuel tank side) of the fuel filler hose so that the remaining length of screw thread becomes 8 to 12 mm (0.31 to 0.47 in).
- Tighten clamp (fuel filler tube side) of fuel filler hose so that the remaining length of screw thread becomes 5.7 to 9.7mm (0.22 to 0.38 in).
- To connect quick connector, Refer to "Quick Connector".

INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch "ON" (with engine stopped), and check connections for leakage by applying fuel pressure to fuel piping.
2. Start engine and check for fuel leaks at the fuel system tube and hose connections.