Fuel tank system

A method of manufacturing a fuel tank system, comprising:

• forming a tank with at least one tube holder arranged inside the tank and with an internal venting conduit that extends through a neck of the tank and through the at least one tube holder;
• connecting a distal end of a conduit to a shutoff valve;
• inserting the shutoff valve through the neck and into the tank;
• attaching a clip of the shutoff valve to the internal venting conduit, such that the internal venting conduit and the at least one tube holder support the shutoff valve inside of the tank and couple the shutoff valve to the interior of the tank;
• and
• arranging the direct fill assembly in the neck of the tank and connecting a proximal end of the internal venting conduit to a first venting channel of the direct fill assembly, wherein:
• the direct fill assembly includes an upper end, a lower end, a first venting channel, and a second venting channel, the second venting channel extending between the lower end and the upper end and venting gas accumulating proximate to the lower end, the first venting channel connected to the internal venting conduit that extends through the interior volume of the tank and venting from a distal end of the internal venting conduit.

A method of assembling a direct fill assembly, comprising:

• providing a sleeve of the direct fill assembly and a receiver of the direct fill assembly;
• installing a venturi sub-assembly in a central bore of the sleeve and installing the receiver in the central bore of the sleeve, wherein the installing the venturi sub-assembly further comprises:
• inserting a lower end of the venturi sub-assembly in an upper end of a lower conduit of the sleeve, such that a passageway extending through a body of the venturi sub-assembly is in communication with and alignment with an inner passageway of the lower conduit;
• installing a fluid limiting float valve in the second venting channel, wherein the second venting channel extends through the sleeve from a top end towards a bottom end, and wherein the installing the fluid limiting float valve in the second venting channel further comprises securing a float in the second channel via a float cap that is inserted into a bottom opening of the second venting channel and retained in the bottom opening via a rivet;
• installing a check valve on the bottom end of the sleeve;
• and
• securing the receiver to the sleeve via a rivet.