SAFARI

FUEL SYSTEM

Introduction :

The Diesel vehicle fuel system consists of following

components :

1. Fuel tank assy.

2. Fuel tank strainer.

3. Fuel sedimeter

4. Fuel filter (on Engine)

5. Fuel level gauge.

6. Fuel filler cap

7. Fuel hoses and fuel lines (i.e. delivery & return

lines)

Warning :

While removing the fuel tank from the vehicle,

keep sparks, cigarettes, and open flame away from

it.

Before repairing fuel tank assy., clean it thoroughly

Always wear safety glasses.

FUEL TANK

The fuel tank is located behind the rear axle of the

vehicle. (Fig. 2)

Removal

1. Remove the fuel tank cap.

2. Drain the fuel from the fuel tank before removing

the tank from the vehicle via drain plug. Do not

drain or store fuel in an open container to avoid

possibility of fire or explosion. Put lid on container.

Unscrew banjo bolt and disconnect suction line

from fuel tank strainer.

3. Unscrew banjo bolt and disconnect suction line

from fuel tank. (Fig. 3)

3a. Remove QC connection on tank top.

4. Disconnect the fuel gauge unit connector.(Fig. 3c)

5. Disconnect the fuel filler neck and connecting

hose Remove the clamp assy.(Fig. 3a)

6. Loosen the fuel tank mounting screws1, 2, 3 & 4

and take out the tank from vehicle.(Fig. 2)

Inspection

1. After removing fuel tank, visually inspect fuel tank

for deterioration, leaks and damage. Replace if

necessary.

Note :

Any repair on fuel tank using external heat or

flame may result in personal injury or damage.

Fig.2

Fig.3

Fig. 3a

FUEL GAUGE UNIT

CONNECTOR

RETURN

CONNECTOR

SUCTION

CONNECTOR