Fuel Tank: Service and Repair

Exploded View FL-5:

Exploded View

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY

FUEL TANK

Exploded View FL-10:

Exploded View

Removal and Installation

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

REMOVAL
- 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. Refer to "Exploded View FL-5".
2. Remove exhaust front tube, center muffler and main muffler.
3. Remove propeller shaft.
4. Remove parking rear brake cables.
5. Remove rear suspension assembly.
6. Remove fuel tank protector.




7. Disconnect fuel filler hose (1), vent hose (2) and EVAP hoses (3) at fuel tank side.

4: Fuel tank protector
<=: Vehicle front




8. Support the lower part of fuel tank (1) with transmission jack (A).

CAUTION: Support the position that fuel tank mounting bands do not engage.

9. Remove fuel tank mounting bands.
10. Supporting with hands, descend transmission jack carefully, and remove fuel tank.

CAUTION:
- Make sure that all connection points have been disconnected.
- Confirm there is no interference with vehicle.

11. Remove fuel filler tube, as necessary.

INSTALLATION
Note the following, and install in the reverse order of removal.
- Surely clamp fuel hoses and insert hose to the length.

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 the clamp hand with the top mark until the mark is on the bolt head flange "A".
- To connect quick connector, refer to "Quick Connector".

Inspection

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 rev it up and make sure there are no fuel leaks at the fuel system tube and hose connections.

- After removing/installing rear suspension assembly, make sure to adjust wheel alignment and then, adjust neutral position of steering angle sensor. Refer to RSU-6, "Wheel Alignment Inspection" Suspension and STC-27, "4WAS FRONT ACTUATOR NEUTRAL POSITION ADJUSTMENT: Description". Testing and Inspection