Fuel Tank: Service and Repair

WARNING
- Fuel vapor Is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures."
- Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

Removal/Inspection/Installation
1. Drain the fuel from the fuel tank.
2. Remove in the order shown in the figure below.
3. Inspect the fuel tank components visually and repair or replace if necessary.
4. Install in the reverse order of removal, referring to Installation Note.





1. Battery cable
2. Fuel hoses (see Installation Note)
3. Evaporative hoses (see Installation Note)
4. Under cover
5. Fuel filler pipe
6. Fuel tank strap
7. Fuel tank (Inspect for cracks and corrosion)
8. Check valve
9. Separator (Inspect for cracks and corrosion)
10. Fuel vapor valve
11. Fuel pump
12. Nonreturn valve




Installation Note
1. Push the ends of the main fuel hose, fuel return hose, and evaporative hoses onto the fuel tank fittings at least 25 mm (1.0 in).
2. Push the fuel filter hose onto the fuel tank pipe and filter pipe at least 35 mm (1.4 in).
3. Push the evaporative hoses onto the fuel vapor valve at least 20 mm (0.8 in).
4. Push the evaporative hoses onto the check valve at least 17 mm (0.7 in).
5. Connect the fuel filler hose and breather hose onto the fuel tank as shown in the figure.




Nonreturn Valve
Verify that the nonreturn valve operates under its own weight as shown in the figure.