Fuel Tank: Service and Repair

REMOVAL AND INSTALLATION




CAP INSTALLATION
Use the special tool to tighten the cap to the specified torque so that the marks on the fuel tank and the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) are aligned.

CAUTION: Make sure that the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) does not turn together with the cap when tightening the cap. If the mating marks are not aligned, the position of the float will not be correct and the fuel gauge indicator light and the fuel level gauge will not operate properly.

FUEL TANK DIFFERENTIAL PRESSURE SENSOR INSTALLATION




CAUTION: When removing or installing the sensor, take care not to damage sealing.




FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK
(1) Disconnect the fuel tank differential pressure sensor connector and connect the special tool between the terminals of the disconnected connector.
(2) Turn the ignition switch to ON and take a reading of the following output voltage.

Between terminals (2) and (3) Standard value: 2.0-3.0 V




FUEL CUT OFF VALVE CHECK
If the sound of the float valve moving (knocking sound) can be heard when the valve assembly is gently shaken up and down, then the valve is okay.




LEVELING VALVE CHECK
(1) Check that the leveling valve is at the open position when it is held vertically.
(2) Check that the leveling valve is at the close position when it is tilted.




FUEL GAUGE UNIT AND PUMP ASSEMBLY REPLACEMENT
(1) Remove the rear seat cushion.
(2) Remove the protector.
(3) Bleed the residual pressure from inside the fuel pipe line to prevent the fuel from spraying out.




(4) Disconnect the hose and connector connections, and then remove the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly.




(5) Check to be sure that the fuel tank packing is not damaged or deformed, and then securely install the packing.

NOTE: If the packing is damaged or deformed, replace with new packing.

(6) Apply soapy wafer to the inside of the packing, and then install the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly.

CAUTION: Do not tilt the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly when installing.

(7) After applying soapy water to the outside thread of the fuel tank. Use the special tool to tighten the cap to the specified torque so that the marks on the fuel tank and the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) are aligned.

CAUTION: Make sure that the fuel gauge unit and pump assembly (or the fuel gauge unit and pipe assembly) does not turn together with the cap when tightening the cap. If the mating marks are not aligned, the position of the float will not be correct and the fuel gauge indicator light and the fuel level gauge will not operate properly.

CAUTION: The packing should be installed as shown in the illustration.

(8) Check for leaks from the installation section of the fuel gauge unit and pump assembly or the fuel gauge unit and pipe assembly by the following procedure.
1. Apply soapy water to the circumference of the cap.
2. Choke the vapor hose and main hose, apply an internal pressure of 10 kPa (1.5 psi) or less from the return hose and check to be sure that no bubbles form in the soapy water.




FUEL SHUT-OFF VALVE CHECK
Check that the flapper and valve open and close as shown in the illustration.