Removal and Replacement

Fuel Tank Replacement

Removal Procedure





Caution: Refer to Relieving Fuel Pressure Caution Technician Safety Information.

1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Service and Repair.

Caution: Refer to Battery Disconnect Caution Battery Disconnect Caution.

2. Disconnect the negative battery cable.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedures.
4. Remove the front muffler. Refer to Muffler Replacement (Front) Muffler Replacement (Front)Muffler Replacement (Rear) Muffler Replacement (Rear).




5. Disconnect the fuel tank filler tube.




6. Disconnect the fuel line near the right front of the fuel tank.




7. Remove the rear seat. Refer to Rear Seat Cushion Replacement Rear Seat Cushion Replacement.
8. Remove the fuel pump access cover.




9. Disconnect the electrical connector at the fuel pump assembly.
10. Disconnect the fuel line.




11. Remove the parking brake cables support bracket bolt.
12. Remove the parking brake cables from the fuel tank.




13. Disconnect the fuel vapor line from the solenoid valve.




14. Support the fuel tank.
15. Remove the fuel tank strap retaining nuts.
16. remove the fuel tank strap.
17. Carefully lower the fuel tank.
18. Remove the fuel tank.
19. Transfer any parts as needed.

Installation Procedure




1. Raise the fuel tank into position.
2. Install the fuel tank straps.

Notice: Refer to Fastener Notice Fastener Notice.

3. Install the fuel tank strap retaining nuts.

Tighten the fuel tank strap retaining nuts to 20 Nm (15 lb ft).




4. Connect the fuel vapor line from the solenoid valve.




5. Install the parking brake cables support bracket.
6. Install the parking brake cables from the fuel tank.




7. Connect the fuel line.
8. Connect the electrical connector at the fuel pump assembly.




9. Install the fuel pump access cover.
10. Install the rear seat. Refer to Rear Seat Cushion Replacement Rear Seat Cushion Replacement.




11. Connect the fuel line near the right front of the fuel tank.




12. Connect the fuel tank filler tube.
13. Install the fuel tank filler tube clamp at the fuel tank.




14. Install the front muffler. Refer to Muffler Replacement (Front) Muffler Replacement (Front)Muffler Replacement (Rear) Muffler Replacement (Rear).
15. Connect the negative battery cable.
16. Fill the fuel tank.
17. Perform a leak check of the fuel tank and the fuel line connections.

Removal Procedure





Caution: Refer to Relieving Fuel Pressure Caution Technician Safety Information.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.





Caution: Refer to Battery Disconnect Caution Battery Disconnect Caution.

2. Disconnect the negative battery cable.
3. Remove the rear seat. Refer to Rear Seat Cushion Replacement Rear Seat Cushion Replacement.
4. Remove the fuel pump access cover.
5. Disconnect the electrical connector at the fuel pump assembly.
6. Disconnect the fuel line.




7. Remove the fuel pump assembly clip.
8. Remove the fuel pump assembly from the tank.

Installation Procedure




1. Clean the gasket mating surface on the fuel tank.
2. Position the new gasket in place.
3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.




4. Install the fuel pump assembly clip.
5. Connect the fuel pump assembly connector.
6. Install the fuel pump line.




7. Install the fuel pump access cover.
8. Connect the negative battery cable.
9. Perform an operational check of the fuel pump.
10. Install the rear seat. Refer to Rear Seat Cushion Replacement Rear Seat Cushion Replacement.