Fuel Tank: Description and Operation

Fuel Tank

The fuel tank is located on the underside of the vehicle, forward of the rear suspension subframe. The tank is constructed from moulded plastic and is retained by a tubular cradle which is secured to the vehicle floorpan with four bolts. A heat shield is installed on the LH side of the support cradle to protect the tank from heat radiated by the exhaust system. A fire shield is installed on the RH side of the support cradle.

The fuel tank has a nominal capacity of 60 liters (15.85 US gallons). An aperture in the top surface of the tank allows for the fitment of the fuel pump.

On vehicles from 2002.5 model year - The fuel tank capacity is increased by 4 litres (0.8 gallons) to 64 liters (14.0 gallons). This is achieved by modifications to the tank venting system.

The top of the fuel tank filler tube is located in the RH rear wing panel and is closed by a lockable filler cap. The bottom of the filler tube is connected to the tank by a flexible tube secured with clamps. On NAS vehicles, a flap valve in the fuel tank, at the connection point with the filler tube, prevents vapour from escaping once refuelling is completed and also prevents fuel from escaping if the filler cap or filler tube are damaged in an accident.

On all except NAS vehicles, a vent pipe between the tank and the neck of the filler tube allows air to escape from the tank during refuelling. With the fuel filler cap installed, the tank is ventilated to atmosphere through vent pipes that connect three roll over valves in the tank to the Evaporative emissions (EVAP) system.

On NAS vehicles, during refuelling and with the fuel filler cap installed, the tank is ventilated to atmosphere through vent pipes that connect an On-board Refuelling Vapour Recovery (ORVR) valve and the three roll over valves in the tank to the Evaporative emissions (EVAP) system.

The location of the vent pipe connections on the fuel tank ensures an air space remains in the tank after filling, to allow for heat expansion of the fuel.

The ORVR valve and roll over valves are float valves that prevent fuel from entering the EVAP system vent pipes due to fuel slosh or if the vehicle overturns.

On vehicles from 2002.5 model year - Modifications are introduced to increase the capacity of the fuel tank. The modification comprises a change to the vent line from the forward ROV. The vent line from the ROV now connects to the vent line between the two-way valve and the vapour separator. Venting from the forward ROV is no longer restricted by the two-way valve. The ROV now controls the refuelling nozzle shut-off. When the ROV closes, pressure in the tank increases shutting off the refuelling nozzle. This modification allows an additional 5 liters (1.1 gallons) of fuel to be added to the tank.

On NAS vehicles from 2002.5 model year - The fuel tank on NAS vehicles has a fabric sleeve fitted to the filler pipe inlet in the tank. This reduces the amount of vapour produced during refuelling and subsequent load on the EVAP canister.

NOTE: When defuelling the tank with a vacuum pump, the fabric sleeve can become inverted and may initially cause problems during subsequent refuelling by shutting off the refuelling nozzle prematurely. After several attempts at refuelling, the fabric sleeve should straighten out and allow refuelling as normal.