Fuel Tank: Service and Repair

WARNING:
- Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Pressure Release Procedure".

Fuel Pressure Release

- Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

1. Disconnect the negative battery cable.
2. Remove the drain plug and drain the fuel from the fuel tank.
3. Remove the rear seat cushion.
4. Remove in the order shown in the figure.
5. Install in the reverse order of removal, referring to Installation note.
6. After installation, verify that the fuel tank is securely fixed.




STEP 1
1. Fuel pump cover.
2. Fuel hose.
3. Evaporative hose.

INSTALLATION NOTE: Push the ends of the evaporative hose onto the respective fittings at least 20 mm (0.79 in.).

4. Breather hose.




NOTE: Push the ends of the fuel hoses, evaporative hoses, and breather hose onto the respective fittings. Be sure the hoses are not bent or twisted.

Specification: 25 - 3O mm (0.99 - 1.18 in)


5. Joint hose.

NOTE: Push the ends of the joint hose onto the fitting. Be sure the hose is not bent or twisted.

Specification: 35 - 40 mm (1.38 - 1.57 in)

- Install the clamps on the joint hose as shown.
- Position the tabs of each clamp within the allowable range.

Allowance
"C": 10° to both directions
"D": 90° to right


6. Fuel tank strap.
7. Fuel tank.
8. Protector.
9. Dust cover.
10. Fuel filler pipe.




STEP2
1. Pad.




INSTALLATION NOTE: Stick pad "A" onto the fuel tank, over the harness (California only) and the fuel pipe as shown.
Stick pads "B" and "C" onto the fuel tank as shown. (Upper surface of the fuel tank is projected for installation of pads "C"). Be sure the hoses are not bent or twisted.

2. Fuel pipe, rollover valve.
3. Tank pressure control valve.
4. [1][2]Fuel tank pressure sensor.
5. Charcoal canister.
6. Fuel pump.
7. Inlet pipe.

NOTE: Remove the inlet pipe only when replacing the non-return valve.

8. Insulator.