Fuel Tank: Service and Repair

REMOVAL




1. To reduce the internal pressure of the fuel main pipes and hose, first start the engine and then disconnect the electrical fuel pump connector in the rear seat side.

CAUTION: Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose, otherwise fuel will spill out, leading to the risk of fire or explosion.




2. Disconnect the battery cable from the negative terminal of the battery.

3. Remove the fuel tank cap.




4. Disconnect the return hose and vapor hose.

5. Disconnect the fuel sender connector.




6. Disconnect the high pressure hose from the fuel tank.




7. Loosen the two self-locking nuts, that hold tank in the position and remove the two tank bands.

8. Detach the fuel filler hose and leveling hose.




9. 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. Check the fuel tank inside 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. Using a vacuum hand pump, check the operation of the two-way valve.

INSTALLATION




1. Connect the leveling hose to the tank and approximately 40 mm (1.6 in.) at the filler neck.

2. When connecting the filler hose, connect the end with the shorter straight pipe to the tank side.




3. Confirm that the pad is fully bonded to the fuel tank. 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.




4. Connect the vapor hose and return hose. Attach the fuel hose to the line as shown in the illustration.




5. To connect the high pressure hose to the fuel pump, temporarily tighten 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 (300 - 400 kg.cm, 22-29 lb.ft)

NOTE: 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 sender connector.