Fuel Tank: Service and Repair

REMOVAL

Fuel Tank R&R:

WARNING: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

WARNING: Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries, damage or death. Fuel can also irritate skin and eyes.

WARNING: Repairing a fuel tank that has not been properly steam cleaned is dangerous. Explosion or fire may cause serious injury or death. Always properly steam clean a fuel tank before repairing it.

Remove tank assembly in this order:

1. Pre-silencer.
2. Insulator.
3. Connector.
4. Fuel hoses.
5. Evaporative hoses.
6. Fuel tank straps.
7. Fuel tank.

TANK DRAINING

Fuel Tank Draining:

1. Remove fuel pump relay.
2. Start and run engine until it stalls. Switch ignition OFF.
3. Install fuel pump relay.
4. Remove filler cap and insert hose into tank through filler pipe.
5. Use an approved pumping device and storage container to remove fuel from tank.

NOTE: For easier work, prepare a hose with outer diameter of 0.51 in (13 mm), length of 85 in (2160 mm).


INSTALLATION

Fuel Hose Installation:

1. Install in reverse order of removal.
2. Push ends of main fuel hose, fuel return hose, and evaporative hoses onto tank fittings at least 1.0 in (25 mm).
3. Push fuel filler hoses onto tank and filler pipes at least 1.4 in (35 mm).