Fuel Tank: Service and Repair

FUEL TANK COMPONENTS

REMOVAL
1. Remove the rear seat cushion.




2. 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.

3. After the engine is stopped, turn OFF the ignition key, then connect the fuel pump connector again.
4. After disconnecting the high pressure hose and the return hose, connect the proper hose to the fuel pump and drain the fuel about 1/2 of the fuel tank.




5. Disconnect the battery cable form the negative terminal of the battery.
6. Lift up the vehicle.
7. Detach the fuel filler hose and leveling hose.
8. Support the fuel tank with a jack.




9. Remove the fuel tank bands.
10. Remove 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. Check the inside of the fuel tank for dirt or foreign material.
5. Check the in-tank fuel filter for damage or restriction.
6. Test the one-way valve for proper operation.




7. To check the one-way valve, lightly breathe into the inlet and outlet. If air passes one-way only, then the valve is good.

INSTALLATION




1. Confirm the pad if fully bonded to the fuel tank, and install the fuel tank by tightening the self-locking nuts.




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, ensure that the hose is attached as shown in the illustration above.




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

High Pressure Hose Flare Nut.
Tightening Torque: 30-40 Nm (22.1-29.5 lb.ft.)

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




6. Re-connect the electrical fuel pump connector.