Fuel Tank: Service and Repair
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.
- 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.
CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign materials.
1. Level the vehicle.
2. Complete the "BEFORE REPAIR PROCEDURE".
Fuel System Before Repair Procedure
3. Disconnect the negative battery cable.
4. Remove the rear seat cushion.
5. Remove the service hole cover.
6. Remove the fuel pump unit.
7. Siphon the fuel from the fuel tank.
8. Remove the presilencer.
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Complete the "AFTER REPAIR PROCEDURE".
Fuel System After Repair Procedure
Plastic Fuel Hose Disassembly Note
Squeeze the tabs on the quick release connector and disconnect the plastic fuel hose from the fuel pipe.
Nonreturn Valve Installation Note
Align the nonreturn valve with the notch in the fuel-filler pipe as shown, then install.
Plastic Fuel Hose Assembly Note
NOTE:
- A checker tab is integrated with the quick release connector for new plastic fuel hoses.
- The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.
1. Inspect the plastic fuel hose and fuel pipe sealing surface for damage and deformation, and replace as necessary.
- If the quick release connector O-ring is damaged or has slipped, replace the plastic fuel hose.
2. Push the quick release connector into the fuel pipe until a click is heard.
3. Pull the quick release connector by hand and verify that it is installed securely.
Breather Hose Installation Note
Fit the breather hose onto the respective fittings with in the specification, and install clamps as shown.
Specification: 10 mm (0.39 in)
Joint Hose Installation Note
Fit the joint hose onto the respective fittings within the specification, and install clamps as shown.
Specification: 35 - 40 mm (1.4 - 1.5 in)
Evaporative Hose Installation Note
Fit evaporative hose onto the respective fittings within the specification, and install clamps as shown.
Specification: 10 mm (0.39 in)