Fuel Tank: Service and Repair

REMOVAL
1. Relieve fuel pressure in fuel feed line.

CAUTION: This work must not be done when engine is hot. If done it may cause adverse effect to catalyst.

2. Disconnect negative cable at battery.




3. Insert hose of a hand operated pump into fuel filler hose and drain fuel in space "A" in the figure (drain fuel through it till fuel stops).

CAUTION: Do not force hose of a hand operated pump into fuel tank. Doing so can damage inlet valve.




4. Remove fuel tank filler hose protector.
Disconnect filler hose from fuel tank and breather hose from fuel filler neck.

5. Remove fuel tank inlet valve.
Use care not to damage inlet valve when removing.

6. 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.




7. Disconnect fuel filter inlet hose from filter.




8. Disconnect fuel vapor hose and return hose from pipes.

9. Remove fuel tank protector from vehicle.




10. Lower fuel tank gradually while holding it horizontally and pull out each coupler from fuel pump and fuel tank pressure sensor.

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 and fuel pump assembly 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.




INSTALLATION
1. Install fuel pump assembly and fuel cut valve to fuel tank. Refer to "FUEL PUMP".
2. Connect fuel hoses to fuel tank, fuel cut valve and fuel pump assembly.
After connecting, clamp hoses securely.

3. Install inlet valve to fuel tank.
If deformed or damaged in any other way, replace with a new one.

4. Install fuel tank by using fuel tank belts and then install protector to vehicle.

Tightening Torque
(a): 50 Nm (5.0 kg.m, 36.5 lb.ft)

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

Tightening Torque
(b): 2.0 Nm (0.2 kg.m, 2.0 lb.ft)
(c): 4.0 Nm (0.4 kg.m, 3.0 lb.ft)

6. Install fuel filler hose protector.




7. Connect fuel vapor hose and return hose to fuel pipe.
Clamp them securely.




8. Connect fuel filter inlet hose to fuel filter.
9. Connect coupler to fuel pump assembly and tank pressure sensor respectively.
10. Connect negative cable to battery.
11. Upon completion of installation, check fuel system for leakage.