Fuel Tank: Service and Repair

FUEL TANK REMOVAL/INSTALLATION [L3 WITH TC]

WARNING:
- Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
- 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, do not damage the sealing surface of the fuel pump unit when removing or installing.
- 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.

CAUTION:
- Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1. Level the vehicle.

2. Complete the "BEFORE SERVICE PRECAUTION". Before Service Precaution

3. Disconnect the quick release connector. Quick Release Connector Removal/Installation






4. Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.

5. Drain the fuel from the fuel tank using the following procedure:

Using M-MDS
- Connect the M-MDS to the DLC-2.





- Using the simulation function "FP", start the fuel pump. On-Board Diagnostic Test

Without using M-MDS
- Remove the battery cover. Removal and Replacement
- Disconnect the negative battery cable. Removal and Replacement
- Remove the fuel pump relay.






CAUTION:
- Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.

- Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.





- Connect the negative battery cable and operate the fuel pump. Removal and Replacement

CAUTION:
- The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

6. Stop the fuel pump using the following procedure.

Using M-MDS
- Using the simulation function "FP", stop the fuel pump. On-Board Diagnostic Test
- Remove the battery cover. Removal and Replacement
- Disconnect the negative battery cable. Removal and Replacement

Without using M-MDS
- Disconnect the negative battery cable to stop the fuel pump. Removal and Replacement

7. To remove the fuel pump unit, remove the following parts:
a. Rear seat cushion Rear Seat Cushion Removal/Installation

b. Service hole cover






c. fuel pump unit connector

8. Remove the middle pipe. Service and Repair

9. Remove the under cover. Service and Repair

10. Remove the insulator (middle No.1). Service and Repair

11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Complete the "AFTER SERVICE PRECAUTION". After Service Precaution









Breather Hose Removal Note

1. Disconnect the breather hose of fuel tank side.

2. Remove the following parts as a single unit.

- Fuel tank
- Breather hose
- Fuel pump unit
- Fuel hose

3. Remove the breather hose.

Fuel-Filler Pipe Removal Note

1. Remove the rear tire (RH). Service and Repair

2. Remove the fuel-filler pipe.

Breather Hose Installation Note

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






Joint Hose Installation Note

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