Fuel Tank: Service and Repair

Fuel Tank Replacement

Removal
1. Relieve the fuel pressure.
2. Remove the fuel fill cap.




3. Remove the spare tire lid, and the access panel (A) from the floor. Disconnect the fuel tank 5P connector (B).
4. Remove the fuel pump unit.
5. Siphon the fuel from the fuel tank into a suitable container with a hand pump.
6. Loosen the rear wheel nuts slightly, then raise the vehicle and make sure it is securely supported. Remove the rear wheels.
7. Release the parking lever fully.
8. J32A1 engine: Remove exhaust pipe B from the catalytic converter.
J32A2 engine: Remove exhaust pipe B from the catalytic converter.
9. Remove the heat insulator cover (A).




10. Remove the fuel pipe cover (A).
11. Disconnect the fuel fill neck tube (B), the fuel tank vapor recirculation tube (C) and the ORVR signal tube (D) from the fuel fill pipes (E).




12. Disconnect the fuel tank vapor vent tube (A) and the quick-connect fittings (B).
13. Disconnect the hose (C).
14. Remove the hose from the pipe holder (D).
15. Disconnect the hose (E) from the EVAP two-way valve (F).
16. Remove the pipe holder (G).




17. Disconnect the wheel sensor 2P connectors (A) if not, go to step 18.




18. Remove the stabilizer bar (A), the heat shield (B) and the parking brake cable bracket (C).




19. Remove the bolt (A), two caliper bolts (B) and caliper body (C).




20. Hook the caliper body (A) to the damper spring (B) with a wire.
21. Remove the parking brake cable.




22. Remove the flange bolt (A).




23. Place a jack, or support, under the rear suspension sub frame. Remove the mounting bolts (A). Remove the rear suspension sub frame.




24. Remove the bolts (A), and the fuel tank straps (B).
25. Remove the lines from the fuel line clip (C).
26. Lift the fuel tank out of the sub frame.

Installation




1. Install the fuel tank straps (A), and tighten the bolts (B). Install the hose to the pipe holder (C).




2. Place the jack, or support, under the rear suspension sub frame. Install the rear suspension sub frame, aligning the pins (A) with the holes in the rear suspension sub frame.
3. Install the remaining parts in the reverse order of removal.
4. After installing, adjust the wheel alignment.