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10. Subtract 25-50 mm (1-2 in.) from the bottom depth
mark and scribe another mark on the fuel supply
line to indicate the new depth requirement.
11. Cut the fuel return line and the fuel supply line to the
new required depth as previously indicated. See
Figure 3-5.
2
1. Fuel return line
2. Fuel supply line
Figure 3-5 Cut Fuel Lines to Required Depth
12. Locate the drilled hole on the top of the fuel tank.
13. Place the preassembled bulkhead seal into the
newly drilled hole. See Figure 3-4.
Note: The fuel return line may temporarily need to
be moved upward through the top of the
bulkhead assembly for easier installation
into the fuel tank hole.
Note: To ensure that the bend of the fuel supply
hoses run along the center line length of the
tank, arrange the fuel lines so that the
supply line outlet and return line inlet are
both positioned at 90° degrees relative to
the center line of the fuel tank and pointed
toward the inside of the vehicle.
Figure 3-6.
1
1. Fuel supply line
2. Fuel return line
3. Mounting bolt, 1/4-20 (with washer)
Figure 3-6 Secure Bulkhead Seal
TP-6583 3/08
1
See
3
2
14. Secure both fuel lines with one hand. Use the other
hand to tighten the 1/4-20 mounting bolt securely.
Note: Ensure both fuel lines do not rotate around the
fuel tank opening when tightening the 1/4-20
mounting bolt. The mounting bolt is tight when
the fuel lines can no longer be rotated in the
assembly.
3.4.2
Installing the Fuel Hoses
1. Locate the provided 6.4 mm (1/4 in.) dia. fuel return
hose and 8 mm (5/16 in.) dia. fuel supply hose.
2. Split open the hose guard and place it over each
fuel hose. See Figure 3-7.
1. Fuel hose
2. Hose guard
Figure 3-7 Place Hose Guard over Fuel Hose
Note: When applying the hose guard, leave the end of
the fuel hose exposed so the hose clamp can fit
snug onto the fuel hose.
3. Place a hose clamp over the 8 mm (5/16 in.) dia.
fuel supply hose.
4. Slide the 8 mm (5/16 in.) dia. fuel supply hose over
the fuel supply line. See Figure 3-8.
2
1
1. Fuel supply line
2. Hose clamp, qty. 2
3. Fuel return hose, 6.4 mm (1/4 in.) dia. with hose guard
4. Fuel supply hose, 8 mm (5/16 in.) dia. with hose guard
5. Fuel return line
Figure 3-8 Attach Fuel Hoses to Fuel Lines
1
2
5
3
4
Section 3 Fuel System
17
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