Fuel Tank: Service and Repair

WARNING: When replacing fuel line parts, be sure to observe the following.
- Be sure to furnish workshop with a CO2 fire extinguisher.
- Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
- Be sure to disconnect battery ground cable before conducting operations.
- Put drained fuel in an explosion-proof container and put lid on securely.


CAUTION: Before removing fuel line parts carry out the following procedures:
a. Put drained fuel in an explosion-proof container and put the lid on securely.
b. Release fuel pressure from fuel line. Refer to "Fuel Pressure Release".
c. Disconnect battery ground cable.
- When installing fuel check valve, be careful of its designated direction.
- Always replace O-ring and clamps with new ones.
- Do not kink or twist tubes when they are being installed.
- Do not tighten hose clamps excessively to avoid damaging hoses.
- After installing tubes, run engine and check for fuel leaks at connections.
- Use only a genuine fuel filler cap as a replacement.

Fuel Pump Relay Location:

2 + 2
1. Disconnect the fuel pump relay.
2. Start engine.
3. When engine stalls, crank or attempt to restart engine 2 or 3 times to release pressure.
4. Turn ignition switch off and reinstall fuel pump relay.

Fuel Tank Assembly:

5. Disconnect fuel pump and gauge electrical connector from inside luggage compartment.
6. Siphon fuel into suitable container.
7. Disconnect fuel pump and fuel gauge electrical connections.
8. Disconnect filler neck from body.
9. Remove fuel supply, return, and evaporative lines.
10. Using a suitable jack, support fuel tank.
11. Remove fuel tank mounting straps and lower tank from vehicle.
12. Reverse procedure to install.

Fuel Pump Relay Location:

2 Seater
1. Disconnect the fuel pump relay.
2. Start engine.
3. When engine stalls, crank or attempt to restart engine 2 or 3 times to release pressure.
4. Turn ignition switch off and reinstall fuel pump fuse.
5. Disconnect fuel pump and gauge electrical connector from inside luggage compartment.
6. Siphon fuel into suitable container.
7. Disconnect fuel pump and fuel gauge electrical connections.

Fuel Tank Removal:

8. Disconnect filler neck from body.
9. Remove fuel supply, return, and evaporative lines.
10. Using a suitable jack, support fuel tank.

Fuel Tank Assembly:

11. Remove fuel tank mounting straps and lower tank from vehicle.
12. Reverse procedure to install.