Fuel Tank: Service and Repair

Prior to Removal
- Release pressure from high pressure hose
- Drain fuel from tank

Removal
1. Return hose
2. Vapor hose
3. Clamp
4. Fuel gauge unit connector
5. Electrical fuel pump connector

Caution: Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

6. High pressure fuel hose
7. Filler hose
8. Vapor hose
9. Self-locking nut
10. Tank band
11. Fuel tank
12. Vapor hose
13. Fuel tank pressure control valve
14. Fuel gauge unit
15. Electrical fuel pump
16. Drain plug
17. Fuel tank filler tube cap
18. Packing
19. Fuel filler neck


Inspection
- Check the hoses and the pipes for crack or damage.
- Check the fuel tank filler tube cap for malfunction.
- Check the fuel tank for deformation, corrosion or crack.
- Check the fuel tank for dust or foreign material.

Note: If the inside of the fuel tank is to be cleaned, use any one of the following:
- Kerosene
- Trichloroethylene
- A neutral emulsion type detergent

Installation
1. Fuel filler neck
2. Packing
3. Fuel tank filler tube cap
4. Drain plug






Notes:
a. Align the three positioning projections of the packing with the holes in the fuel pump.
b. When the fuel pump is installed, the holding bolt at the lower side of the fuel tank should be installed first. Care should be taken at this time that the O-ring is not pinched.

5. Electrical fuel pump






Note: Align the two positioning projections of the packing with the holes in the fuel gauge unit.

Caution: When mounting the fuel gauge unit, incline the float at the end leftward, and insert it into the fuel tank. Since the reserver cap is provided in the fuel tank, the fuel gauge unit will contact the reserver cap if the fuel gauge unit is inclined rightward during insertion.

6. Fuel gauge unit






Note: Install so that the [1][2]overfill limiter is facing in the direction shown in the figure.

7. Fuel tank pressure control valve






Note: When attaching the fuel hose to the pipe, be sure that the hose is attached as shown in the illustration.
Standard value: 25-30 mm (1.0-1.2 in.)

8. Vapor hose
9. Fuel tank






Note: When attaching the fuel hose to the pipe, be sure that the hose is attached as shown in the illustration.
Standard value: 25-30 mm (1.0-1.2 in.)

10. Tank band
11. Self-locking nut






Notes:
- The vapor hose should be connected all the way at the tank, and approximately 40 mm (1.6 in.) at the filler neck.
- The end of the filler hose with the shorter straight pipe part should be connected at the tank side.

12. Vapor hose
13. Filler hose






Note: Temporarily tighten the flare nut by hand, and then tighten it to the specified torque, being careful that the high pressure fuel hose does not become twisted.

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


14. High pressure fuel hose
15. Electrical fuel pump connector
16. Fuel gauge unit connector


Note: Tighten the self-locking nuts until the rear end of the tank band contacts the body.

17. Clamp


18. Vapor hose






Note: Install so that the [1][2]overfill limiter is facing in the direction shown in the figure.

19. Return hose