Fuel Tank: Service and Repair

Fuel Tank Replacement

Removal

1. Remove the fuel fill cap.
2. Relive the fuel pressure.
3. Drain the fuel tank: Remove the fuel tank unit. Using a hand pump, hose, and a container suitable for gasoline, draw the fuel from the fuel tank.
4. Remove the brake fluid from the master cylinder reservoir with a syringe.

NOTE: Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

5. Remove the rear tray.




6. Remove the access panel (A) from the floor, and disconnect the fuel tank 5P connector (B).




7. Disconnect both ABS rear wheel sensors 2P connectors (A), and push the connectors out (B).




8. Remove the fuel pipe cover (A), and disconnect the fuel fill neck tube (B), the fuel tank vapor recirculation tube (C) and the fuel tank vapor signal tube (D) from the fuel fill pipes (E).
9. Loosen the rear wheel nuts slightly, then raise the vehicle and make sure it is securely supported.
10. Remove the rear wheels.




11. Remove the bolts from both ABS rear wheel sensor harness brackets (A).




12. Remove both caliper shields (A).




13. Disconnect both parking brake cables (A), and move them out of the way.




14. Disconnect the brake hoses from both rear brake lines using a 10 mm flare-nut wrench.




15. Remove the flange bolt (A) from both rear dampers (B).




16. Remove the canister cover (A), rear suspension stiffener (B), and the propeller shaft (C).




17. Remove the muffler (A).




18. Disconnect the quick-connect fittings (A).




19. Disconnect the fuel tank vapor vent tube (A), then remove the bolt (B) and the EVAP canister (C).




20. Disconnect the hose (A) and fuel vent tube (B), then remove the fuel tank vapor vent tube from the tube holder (C). Remove the bolts (D) and the fuel vent assembly (E).




21. Place a jack or other support under the rear suspension subframe (A). Remove the mounting bolts (B) and the rear suspension subframe (A).




22. Place the jack or support under the fuel tank (A) and remove the mounting bolts (B) and the fuel tank.

Installation

1. Install the fuel tank in the reverse order of removal.
2. After installing, bleed the brake system, and adjust the wheel alignment.
3. Check for fuel leaks.