Fuel Cell Gas Tank Kit Installation Guide
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Fuel Cell Gas Tank Kit Installation Guide
Socket set and ratchet
Combination wrench set
Torque wrench
AN wrench set
Bench vise
Hose cutter
Deburring tool
Hydraulic floor jack and jack stands
Fuel transfer pump
Drain pan
Screwdriver set
Pliers
Marker
Drill and drill bits (if required)
Safety glasses
Fuel-resistant gloves
Combination wrench set
Torque wrench
AN wrench set
Bench vise
Hose cutter
Deburring tool
Hydraulic floor jack and jack stands
Fuel transfer pump
Drain pan
Screwdriver set
Pliers
Marker
Drill and drill bits (if required)
Safety glasses
Fuel-resistant gloves
Read the complete installation manual and the applicable vehicle service manual. Follow only the steps for components included in your kit, and skip sections for components not supplied.
Confirm the vehicle uses an electronic fuel injection (EFI) system.
Inspect the kit and verify all components and hardware are present and undamaged.
Work in a well-ventilated area away from flames, sparks, hot surfaces, and other ignition sources.
Relieve fuel system pressure, turn the ignition OFF, allow the engine to cool, and disconnect the negative battery cable.
Support the vehicle securely with jack stands and keep an approved fire extinguisher nearby.
Confirm the vehicle uses an electronic fuel injection (EFI) system.
Inspect the kit and verify all components and hardware are present and undamaged.
Work in a well-ventilated area away from flames, sparks, hot surfaces, and other ignition sources.
Relieve fuel system pressure, turn the ignition OFF, allow the engine to cool, and disconnect the negative battery cable.
Support the vehicle securely with jack stands and keep an approved fire extinguisher nearby.
1. Relieve fuel system pressure and remove the old fuel filter, fuel pump, and fuel pressure regulator as required.
2. Position and securely mount the fuel cell with clearance from exhaust, suspension, driveshaft, and moving components.
3. Mount the fuel pump close to and preferably at or below the fuel cell, using the supplied bracket and rubber isolators.
4. Install the 100-micron and 10-micron fuel filters in the direction shown by their flow arrows.
5. Mount the fuel pressure regulator away from heat, install the pressure gauge in the 1/8-inch NPT port, and connect the vacuum/boost reference hose if used.
6. Measure, cut, deburr, and assemble the supplied CPE or PTFE fuel hose and AN fittings; pressure-test each completed hose assembly.
7. Connect the return-style system in this order: fuel cell, 100-micron filter, fuel pump, 10-micron filter, fuel rail, fuel pressure regulator, return line, fuel cell.
8. Reconnect electrical connections and secure all hoses and wiring away from heat, sharp edges, and moving parts.
9. Prime the system, check every connection for leaks, start the engine, and adjust fuel pressure only while monitoring the gauge.
10. Test-drive the vehicle and complete the final leak inspection.
2. Position and securely mount the fuel cell with clearance from exhaust, suspension, driveshaft, and moving components.
3. Mount the fuel pump close to and preferably at or below the fuel cell, using the supplied bracket and rubber isolators.
4. Install the 100-micron and 10-micron fuel filters in the direction shown by their flow arrows.
5. Mount the fuel pressure regulator away from heat, install the pressure gauge in the 1/8-inch NPT port, and connect the vacuum/boost reference hose if used.
6. Measure, cut, deburr, and assemble the supplied CPE or PTFE fuel hose and AN fittings; pressure-test each completed hose assembly.
7. Connect the return-style system in this order: fuel cell, 100-micron filter, fuel pump, 10-micron filter, fuel rail, fuel pressure regulator, return line, fuel cell.
8. Reconnect electrical connections and secure all hoses and wiring away from heat, sharp edges, and moving parts.
9. Prime the system, check every connection for leaks, start the engine, and adjust fuel pressure only while monitoring the gauge.
10. Test-drive the vehicle and complete the final leak inspection.
Confirm the fuel cell, pump, filters, regulator, hoses, fittings, wiring, and mounting hardware are secure.
Verify each filter and the fuel pump are oriented in the correct flow direction.
Confirm hoses are not kinked, twisted, under tension, or exposed to exhaust heat, sharp edges, or moving parts.
Prime the fuel system and inspect all connections for leaks before starting the engine.
Adjust fuel pressure only with the gauge connected, then tighten the regulator adjustment jam nut.
Recheck for leaks with the engine warm, after the road test, and again after 50-100 km.
Verify each filter and the fuel pump are oriented in the correct flow direction.
Confirm hoses are not kinked, twisted, under tension, or exposed to exhaust heat, sharp edges, or moving parts.
Prime the fuel system and inspect all connections for leaks before starting the engine.
Adjust fuel pressure only with the gauge connected, then tighten the regulator adjustment jam nut.
Recheck for leaks with the engine warm, after the road test, and again after 50-100 km.
Engine will not start: check the pump fuse, power, wiring, ground, fuel pressure, filter condition, and fuel-line routing.
Low fuel pressure: inspect for leaks, verify filter direction, replace clogged filters, and check regulator adjustment.
High fuel pressure: verify regulator adjustment and inspect the return line for kinks or restrictions.
Fuel leak: switch the ignition OFF immediately, clean spilled fuel, and repair loose or damaged hoses and fittings before operation.
Noisy fuel pump: verify secure mounting, rubber isolation, correct location near the fuel cell, and an unrestricted inlet supply.
Fluctuating fuel pressure: inspect for air leaks and verify the vacuum/boost reference connection.
Low fuel pressure: inspect for leaks, verify filter direction, replace clogged filters, and check regulator adjustment.
High fuel pressure: verify regulator adjustment and inspect the return line for kinks or restrictions.
Fuel leak: switch the ignition OFF immediately, clean spilled fuel, and repair loose or damaged hoses and fittings before operation.
Noisy fuel pump: verify secure mounting, rubber isolation, correct location near the fuel cell, and an unrestricted inlet supply.
Fluctuating fuel pressure: inspect for air leaks and verify the vacuum/boost reference connection.
Inspect the complete fuel system after the initial road test and periodically thereafter.
Recheck all connections after 50-100 km and retighten loose fittings without overtightening AN fittings.
Replace any leaking, damaged, clogged, or improperly installed component before operating the vehicle.
Recheck all connections after 50-100 km and retighten loose fittings without overtightening AN fittings.
Replace any leaking, damaged, clogged, or improperly installed component before operating the vehicle.
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