Fuel Tank: Service and Repair

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 Pressure Release Procedure".

Fuel Pressure Release

WARNING: 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. Syphon the fuel from the fuel tank.
2. Remove in the order shown in the figure.
3. Inspect all parts and repair or replace as necessary.
4. Install in the reverse order of removal.

Fuel Tank Replacement:

1. Connector
2. Fuel hose
3. Evaporative hose
4. Fuel tank strap
5. Fuel tank
6. Check valve (Two-way)

Removal Note
Before removing the fuel tank, drain the fuel from the tank.

Fuel Pump Relay Location:

1. Remove the fuel pump relay.
2. Start the engine.
3. After the engine stalls, turn off the ignition switch.
4. Install the fuel pump relay.

Fuel Removal:

5. Remove the filler cap and insert a hose into the fuel tank through the filler pipe.
6. Start the pump and syphon the fuel into a container.

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

Outer diameter: 13 mm (0.51 in.)
Length: 2,160 mm (85.0 in.)

Fuel Tank Fill Hose Details:

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.).