Fuel Tank: Description and Operation

Fuel Tank And Mounting:

WARNING: To reduce the risk of personal injury, always cover nylon fuel lines with a wet towel using a torch near it. Also, never expose the vehicle to temperatures higher than 115° C (239° F) for more than one hour, or more than 90° C (194° F) for any extended period.
Take care not to nick or scratch the fuel lines. If damaged, they must be replaced.

FUEL TANK

The fuel tank is used to store fuel for the vehicle. The tank is molded from high density polyethylene, and is located in front of the rear wheels on the left side of the vehicle. It is held in place by two metal straps attached to the underbody. The tank shape includes a reservoir to maintain a constant supply of fuel around the fuel pump filter during low fuel conditions and aggressive vehicle maneuvers. A filler neck check-ball tube is installed after the tank is made, and extends from the tank inlet to the reservoir. The check-ball, located inside the tube, prevents fuel from splashing back out the fuel filler neck when refueling.
When working on or near the fuel tank, be sure to observe important information molded on the bottom of the tank.

Fuel Filler Neck And Cap:

FUEL FILLER NECK

To help prevent refueling with leaded fuel, the fuel filler neck has a built-in restrictor and deflector. The opening of the restrictor will accept only the smaller unleaded gasoline nozzle which must be fully inserted to bypass the deflector. Attempted refueling with a leaded fuel nozzle will result in fuel splashing back out of the filler neck.

FUEL TANK FILLER CAP

The fuel tank filler neck is equipped with a screw type cap. The threaded part of the cap requires several turns counterclockwise to remove. The long threaded area was designed to allow any remaining fuel tank pressure to escape during the cap removal operation. A ratchet type torque limiting device prevents over-tightening. To install, turn the cap clockwise until a clicking noise is heard. This signals that the correct torque has been reached and the cap is fully seated.

NOTE: If a fuel filler cap requires replacement, only a cap with the same features should be used. Failure to use the correct cap can result in a serious malfunction of the system.

FUEL AND VAPOR PIPES

Nylon fuel lines are designed to perform the same job as the steel or rubber fuel lines they replace. Nylon lines are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are two sizes used: 3/8" ID for the fuel feed, and 5/16" ID for the fuel return.
The fuel feed and return lines are assembled as a harness. Retaining clips hold the lines together and provide a means for attaching the lines to the vehicle. Quick-connect type fittings are used at the ends of the fuel feed/return lines and at the in-line fuel filter. Sections of the lines that are exposed to chafing, high temperature or vibration are protected with heat resistant rubber hose and/or corrugated plastic conduit.
Nylon fuel lines are somewhat flexible and can be formed around gradual turns under the vehicle. However, if forced into sharp bends, nylon lines will kink and restrict fuel flow. Also, once exposed to fuel, nylon lines may become stiffer and more likely to kink if bent too far. Special care should be taken when working on vehicles equipped with nylon fuel lines.