Fuel Tank: Service and Repair

WARNING:
When replacing fuel line parts, be sure to observe the following:
- Put a "CAUTION: INFLAMMABLE" sign in workshop.
- Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
- Be sure to furnish the workshop with a C02 fire extinguisher.

CAUTION:
- Before removing fuel line parts, carry out the following procedures:
a. Put drained fuel in an explosion-proof container and put lid on securely.
b. Release fuel pressure from fuel line. Refer to "Fuel Pressure Release".
c. Disconnect battery ground cable.

- Remove quick connectors with Commercial Service Tool.
- Always replace O-ring with a new one.
- Do not kink or twist hoses and tubes when installed.
- Do not tighten hose clamps excessively to avoid damaging hoses.
- When installing fuel check valve, be careful of its designated direction. Refer to "EVAPORATIVE EMISSION SYSTEM".
- After installation, run engine and check for fuel leaks at connections.


REMOVAL:
1. Release fuel pressure from fuel line.
Refer to "Fuel Pressure Release".




2. Disconnect battery ground cable.
3. Drain fuel from fuel tank.
4. Disconnect electrical connectors.
5. Remove filler protector.
6. Disconnect filler tube.




7. Disconnect the quick connectors as follows.

CAUTION:
- To prevent damaging fuel lines, remove quick connectors with Tool.
- Keep the connecting portion of the tubes and quick connector clean.

1. Put mating marks on tubes and connectors for correct installation.
2. Hold side of connector, slide tool inside of quick connector to open retainer and pull tube out of quick connector.




8. Remove tank mounting band bolts while supporting fuel tank.




9. Remove fuel tank.

INSTALLATION:




To install, reverse the removal procedure. Connect the quick connectors as follows.
- Be sure that the connecting portion is clean and smooth.
- Align mating marks.
- Insert tube into the center of the connector until you hear a click.




After connecting quick connectors, make sure the connection is firmly made using the following method.
- Pull on the fuel tube and connector to make sure they are firmly connected.
- Start the engine, increase engine speed and verify that there are no leaks.