Fuel Tank: Service and Repair

REMOVE OR DISCONNECT

1. Negative cable at battery.

Fig. 6C-11 Fuel Pump And Level Gauge Couplers:

2. Fuel level gauge and fuel pump lead wire couplers after removing rear bumper cover.

3. To release pressure in fuel tank, remove fuel filler cap and then, reinstall it.

4. Fuel tank filler hose cover, filler hose and fuel tank inlet valve.

5. Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler.

Use hand operated pump device to drain fuel tank.

CAUTION: Never drain or store fuel in an open container due to possibility of fire or explosion.

6. Release fuel pressure in fuel feed line.

Fig. 6C-12 Disconnecting Fuel Filter Inlet Pipe:

7. Fuel filter inlet pipe from filter.

Fig. 6C-13 Disconnecting Hoses:

8. Fuel vapor hose and return hose from pipes.

9. Fuel tank protector.

10. Fuel tank and cover from vehicle.

INSPECT

After removing fuel tank, check hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Also check fuel pump and level gauge gaskets for leaks, visually inspect fuel tank for leaks and damage.

Replace any damaged or malconditioned parts.

FUEL TANK PURGING PROCEDURE

CAUTION: This purging procedure will NOT remove all fuel vapor. Do not attempt any repair on tank where heat or flame is required, as an explosion resulting in personal injury could occur.

The following procedure is used for purging the fuel tank.

1. After removing fuel tank, remove all hoses, 2-way check valve, fuel separator, fuel pump and fuel level gauge from fuel tank.

2. Drain all remaining fuel from tank.

3. Move tank to flushing area.

4. Fill tank with warm water or tap water, and agitate vigorously and drain. Repeat this washing until inside of tank is clean. Replace tank if its inside is rusty.

5. Completely flush out remaining water after washing.

INSTALL OR CONNECT

1. Fuel pump and fuel level gauge to fuel tank. Use new gaskets.

2. Fuel separator, inlet valve and 2-way check valve to fuel tank directing 2-way check valve black nozzle toward fuel separator.

3. Fuel hoses to fuel tank, fuel pump, 2-way check valve and separator.

After connecting, clamp hoses securely.

4. Fuel tank and cover to vehicle.

5. Fuel filler hose and breather hose to fuel filler neck. Clamp them securely.

6. Fuel vapor hose and return hose to fuel pipe. Clamp them securely.

7. Fuel filter inlet pipe to fuel filter.

Use new gaskets and tighten union bolt to specification.

8. Fuel filler hose cover.

9. Fuel pump and level gauge couplers.

10. Rear bumper cover.

11. Negative cable to battery.

12. Upon completion of installation, check fuel system for leakage.