Fuel Tank: Service and Repair

REMOVAL AND INSTALLATION

CAP INSTALLATION
Use the special tool to tighten the cap to the specified torque so that the marks on the fuel tank and the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) are aligned.

CAUTION: Make sure that the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) does not turn together with the cap when tightening the cap. If the mating marks are not aligned, the position of the float will not be correct and the fuel gauge indicator light and the fuel level gauge will not operate properly.




FUEL TANK FILLER TUBE ASSEMBLY CHECK
(1) Connect a clean rubber hose to the port A of the fuel tank filler tube assembly.
(2) Use a screwdriver or similar tool to push the flapper in order to close the valve, and then blow air into the hose. Check that the air does not flow out of the port B.
(3) Use a screwdriver or similar tool to push the portion A shown in the illustration in order to open the valve, and then blow air into the hose. Check that the air flows out of the port B.




FUEL CUT OFF VALVE CHECK
If the sound of the float valve moving (knocking sound) can be heard when the valve assembly is gently shaken up and down, then the valve is okay.




LEVELING VALVE CHECK
(1) Check that the leveling valve is at the open position when it is held vertically.
(2) Check that the leveling valve is at the close position when it is tilted.







FUEL GAUGE UNIT AND PUMP ASSEMBLY REPLACEMENT
(1) Remove the rear seat cushion.
(2) Remove the protector.
(3) Disconnect the hoses and connectors to remove the fuel pump assembly or fuel gauge unit.







(4) Align the packing positioning projections with the holes in the fuel pump assembly.




FUEL SHUT-OFF VALVE CHECK
Check that the flapper and valve open and close as shown in the illustration.