Fuel Tank: Service and Repair

REMOVAL





1. To reduce the internal pressure of the fuel lines and hoses, first start the engine and then disconnect the electrical fuel pump connector.

NOTE: Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose otherwise fuel will spill out.





2. Disconnect the battery cable form the negative terminal of the battery.
3. Remove the fuel tank cap.





4. Remove the drain plug and drain the fuel.





5. Disconnect the return hose and vapor hose.





6. Disconnect the fuel sender connector.





7. Disconnect tile high pressure hose from the fuel tank.





8. Detach the fuel filler hose and leveling hose.





9. Loosen the two self-locking nuts, that hold the tank in position and remove the two tank bands.
10. Remove the fuel vapor hose and the fuel tank.

INSPECTION

1. Check the hoses and the pipes for cracks or damage.
2. Check the fuel tank cap for proper operation.
3. Check the fuel tank for deformation, corrosion or cracking.
4. heck the inside fuel tank for dirt or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the two-way valve for proper operation.





7. To check the two-way valve, lightly breathe into the inlet and outlet. If air passes through after slight resistance, then the valve is good.

INSTALLATION





1. Confirm that the pad is fully bonded to the fuel tank, and install the fuel tank by tightening the self-locking nuts to the tank bands until the rear end of the tank band contacts the body.





2. Connect the leveling hose to the tank and approximately 40 mm (1.6 in) at the filler neck.
3. When connecting the filler hose, the end with the shorter straight pipe should be connected to the tank side.

Vapor Hose Connection Specifications:

4. Connect the vapor hose and return hose. When attaching the fuel hose to the line, be sure that the hose is attached as shown in the illustration.





5. To connect the high pressure hose to the fuel pump, temporarily the flare nut by hand, and then tighten it to the specified torque. Be careful that the fuel hose does not twist.

Tightening torque
High pressure hose flare nut: 30-40 Nm (22.1 - 29.5 ft lb)

CAUTION: When tightening the flare nut, be careful not to bend or twist the line to prevent damage to the fuel pump connection.





6. Connect the electrical fuel pump and fuel gauge unit connector.





7. Tighten the drain plug to the specified torque.

Tightening torque
Drain plug: 15 - 25 Nm (11 - 18 ft lb)