Removal and Installation

Warning: 

NOTE: When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL 

1. Open fuel filler lid.
2. Open filler cap and release the pressure inside fuel tank.
3. Release the fuel pressure from the fuel lines. Refer to Work Procedure .
4. Check the fuel level with the vehicle on a level surface. If the fuel gauge indicates more than the level as shown (1/2 full), drain the fuel from the fuel tank until the fuel gauge indicates a level at or below as shown (1/2 full).

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   • In case the fuel pump does not operate, use the following procedure.

   Insert fuel tubing of less than 25 mm (0.98 in) diameter into the fuel filler tube through the fuel filler opening to drain fuel from the fuel filler tube. Disconnect the fuel filler hose from the fuel filler tube. Insert fuel tubing into the fuel tank through the fuel filler hose to drain fuel from the fuel tank.

   • As a guide, if the fuel tank is full, drain approximately 23-1/2 (6-1/5 US gal, 5-1/10 Imp gal) to reach 1/2 full or less.
5. Remove rear seat cushion assembly. Refer to Removal and Installation - Seat Cushion Assembly .
6. Remove inspection hole cover.

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7. Disconnect harness connector, fuel feed hose, and quick connector from fuel level sensor unit, fuel filter and fuel pump assembly.
   • Remove quick connector in the following procedures.
     • Pinch quick connector square-part (A) with your fingers, and pull out the quick connector (1) by hand.

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     • If quick connector and tube on sender unit are stuck, push and pull several times until they move, and pull out.
   CAUTION:

   • Quick connector can be removed when the tabs are completely depressed. Do not twist it more than necessary.
   • Do not use any tools to disconnected quick connector.
   • Keep resin tube away from heat. Be especially careful when welding near the resin tube.
   • Prevent acid liquid such as battery electrolyte, etc. from getting on resin tube.
   • Do not bend or twist resin tube during installation and disconnection.
   • To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags (A) or something similar.

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   • Do not insert plug, preventing damage on O-ring in quick connector.
8. Remove exhaust main muffler. Refer to Exploded View .
9. Remove the fuel tank protector.
10. Disconnect return line from filler hose.
11. Remove fuel filler hose.
12. Disconnect vent hose from fuel tank.
13. Support the center of the fuel tank (1) with a suitable jack (B) and secure the fuel tank to the jack.

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    CAUTION:

    • Securely support the fuel tank with a piece of wood (A).
    • Fuel tank may be in an unstable condition, due to the shape of the fuel tank bottom. Be sure to secure tank at all times.
14. Remove fuel tank mounting bands (RH/LH).
15. Lower suitable jack carefully to remove fuel tank while holding it by hand.
    CAUTION:

    Fuel tank may be in an unstable condition, due to the shape of the fuel tank bottom. Be sure to secure tank at all times.

16. Remove lock ring for fuel level sensor unit, fuel filter and fuel pump assembly with Tool (A) by turning counterclockwise (if necessary).

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    Tool number (A)	: KV991J0090 (J-45747) (shown)
    	: KV101207S0 (-)

17. Remove fuel level sensor unit, fuel filter and fuel pump assembly (if necessary).
    CAUTION:

    • Do not bend float arm during removal.
    • Do not pollute the inside by residue fuel. Draw out avoiding inclination by supporting with a cloth.
    • Do not cause impacts such by dropping when handling components.

INSTALLATION 

Installation is in the reverse order of removal.

NOTE:

• Do not use any lubrication to aid with the installation of tubes and hoses.
• Before tightening the fuel tank mounting bands, install the filler hose to the length of 35 mm (1.38 in), all other hoses to 25 mm (0.98 in).
• Tighten the clamps until the head of the bolt is on the paint mark on the clamp band.
• Tight mounting band bolts (1) and (2) to specification. Hand tighten mounting band bolt (3). While pushing the tank in the direction shown below, tighten mounting band bolt (4) to specification then mounting band bolt (3).
  Fig 1: Band Bolt Tightening Sequence

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Quick Connector 

Connect quick connector as follows:

1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is heard.
3. After connecting, check that the connection is secure by following method.
   • Visually confirm that the two tabs are connected to the connector.
   • Pull (A) the tube and the quick connector (1) to check they are securely connected.

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