Fuel Tank: Service and Repair

FUEL TANK
Removal / Inspection / 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 leaks 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 Line Safety 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.




A. Drain the fuel from the fuel tank.
B. Remove in the order shown in the figure.
1. Fuel Pump Connector.
2. Fuel Filler Hose, Breather Hose (See "Installation Note").
3. Non-return Valve.
4. Rear Crossmember.
5. Fuel Hoses, Evaporative Hoses (See "Installation Note").
6. Fuel Tank Bracket.
7. Fuel Tank. Inspect for cracks and corrosion

C. Inspect the fuel tank components visually and repair or replace if necessary.
D. Install in the reverse order of removal, referring to "Installation Note".








Installation Note:
1. Push the ends of the main fuel hose, fuel return hose, and evaporative hoses onto the fuel tank fittings at least 25 mm (1.0 in).
2. Push the fuel filler hose onto the fuel tank pipe and filler pipe at least 35 mm (1.4 in).
3. Push the evaporative hoses on to the fuel vapor valve at least 20 mm (0.8 in).
4. Push the evaporative hoses on to the check valve at least 17 mm (0.7 in).
5. Connect the fuel filler hose and breather hose on to the fuel tank as shown in the figure.




Non-Return Valve / Inspection
Verify that the non-return valve operates under its own weight as shown in the figure.