FUEL TANK REMOVAL/INSTALLATION[L3]

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Warning
•  Repairing a fuel tank that has not been properly steam cleaned is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•  A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

1.  Park the vehicle on a level surface.

2.  Perform the "Fuel Line Safety Procedure" referring to the BEFORE SERVICE PRECAUTION. (See BEFORE SERVICE PRECAUTION[L3].)

3.  Disconnect the negative battery cable.

4.  Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION[L3].)

5.  Drain the fuel from the service hole.

6.  Remove the rear tire (LH) (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

7.  Remove the main silencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION[L3].)

8.  Remove in the order indicated in the figure.

9.  Install in the reverse order of removal.

10.  Inspect all parts by performing the AFTER SERVICE PRECAUTION. (See AFTER SERVICE PRECAUTION[L3].)

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1
Joint hose
(See Joint Hose Installation Note.)
2
Breather hose
(See Breather Hose Installation Note.)
3
Fuel tank
(See Fuel Tank Removal Note.)
4
Protector
(See Protector Removal Note.)
5
Fuel-filler pipe
6
Nonreturn valve


Fuel Tank Removal Note

1.  Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

2.  Position the rear differential out of way.

3.  Remove the fuel tank.


Protector Removal Note

Caution
•  Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.
Note
•  The insulator is installed using rivets.
•  When resin stalling the rivet, install the same rivet or M5 bolt and nut.

1.  Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2.  Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Breather Hose Installation Note

1.  Install the breather hose and clamps as shown in the figure.

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Joint Hose Installation Note

1.  Install the joint hose and clamps as shown in the figure.

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