Fuel Tank Removal and Installation

WARNING:
- Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Pressure Release Procedures".
- Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

1. Complete the "BEFORE REPAIR PROCEDURE".




2. Disconnect the negative battery cable.
3. Remove the rear seat cushion.
4. Siphon the fuel from the fuel tank. (See Fuel Drawing Note.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal
7. Complete the "AFTER REPAIR PROCEDURE".

Fuel Drawing Note
1. Remove the fuel-filler cap and insert a hose into the fuel tank through the fuel-filler pipe.
2. Start the pump and siphon the fuel into a container.






NOTE: For easier work, prepare a hose of following size.

Outer diameter 13 mm {0.51 in}

Length 2160 mm {85.04 in}

Fuel Tank Removal Note
1. The fuel tank is divided into the right and left banks, and it is difficult to siphon the fuel completely. Some fuel may be left in either side of the fuel tank.
2. Avoid tilting the fuel tank during removal.




Nonreturn Valve installation Note
1. Align the nonreturn valve with the notch in the fuel-filler pipe as shown, then install.




Fuel-filler Hose Installation Note
1. Fit the joint hose onto the fuel-filler pipe more than 35 mm {1 .4 in}.
2. install clamps as shown.