Removal and Replacement

Fuel Tank Replacement

Removal Procedure

1. Remove the rear seat cushion assembly. Refer to Rear Seat Cushion Replacement (Rear Seat Cushion Replacement).
2. Remove the rear floor service hole cover for AWD.
3. Discharge the fuel system pressure. Refer to Fuel Pressure Relief (Service and Repair).
Warning: Refer to Battery Disconnect Warning (Service Precautions).

4. Disconnect the cable from the negative battery terminal. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair)
5. Disconnect the fuel tank main tube subassembly.
6. Disconnect the fuel tank vent hose for FWD.
7. Remove the fuel pump gage retainer.
8. Remove the right fuel sender gage assembly.
9. Remove the fuel suction tube assembly.
10. Drain the fuel. Refer to Fuel Tank Draining (Procedures)
11. Remove the catalytic converter. Refer to Catalytic Converter Replacement (2.4L AWD) (Service and Repair)Catalytic Converter Replacement (2.4L FWD) (Service and Repair)Catalytic Converter Replacement (1.8L) (Service and Repair).
12. Remove the propeller with center bearing shaft assembly for AWD. Refer to Propeller Shaft Replacement (Service and Repair)




13. Remove the 4 bolts (1, 2, 3, 8) or (4, 5, 6, 7), and separate the parking brake cables.
14. Remove the charcoal canister assembly. Refer to Evaporative Emission Canister Replacement (Service and Repair)




15. Remove the 7 bolts (1-7) and the fuel tank protector for AWD.




16. Remove the 4 bolts (1, 2, 3, 4) and the fuel tank protector sub-assembly for FWD.
17. Remove the rear suspension member subassembly for AWD. Refer to Rear Axle Replacement (Except All Wheel Drive and GT) (Service and Repair)





Note: Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary. It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly. Only disconnect the quick connector by hand. Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.

18. Disconnect the fuel tank vent hose for Torsion Beam Type Suspension.
19. Pinch the tabs of the retainer of the fuel tube connector to remove the lock claws.
20. Pull the fuel tank vent hose out of the pipe.




21. Disconnect the breather tube fuel hose.
22. Remove the checker of the fuel tube connector from the pipe.
23. Pinch the retainer (1) of the fuel tube connector (5), then pull the fuel tube connector out of the pipe (2).




24. Separate the breather tube fuel hose (1).




25. Pinch the tabs of the retainer (1) of the fuel tube connector to remove the lock claws (2) and push it down.
26. Pull the fuel tank main tube out of the pipe.




27. Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.




28. Loosen the hose clamp bolt (1), then disconnect the fuel tank filler pipe hose from the fuel tank.




29. Hold the fuel tank using a transmission jack for AWD.




30. Remove the 4 bolts (1, 2, 3, 4), then remove the 2 fuel tank bands for AWD.
31. Operate the transmission jack, then remove the fuel tank.




32. Hold the fuel tank using a transmission jack for AWD.




33. Remove the 4 bolts (1, 2, 3, 4), then remove the 2 fuel tank bands.
34. Operate the transmission jack, then remove the fuel tank.




35. Remove the fuel tank main tube (1) from the fuel tank.




36. Remove the fuel tank vent hose (1) for AWD.




37. Remove the fuel tank vent hose from the fuel tank clamp (1) for FWD.




38. Remove the fuel tank cushions from the fuel tank.

Installation Procedure




1. Install the new fuel tank cushions onto the fuel tank.




2. Install the fuel tank vent hose (1) for AWD.




3. Install the fuel tank vent hose onto the fuel tube clamp (1) for FWD.




4. Install the fuel tank main tube (1) onto the fuel tank.
5. Install the fuel tank assembly for AWD.
6. Set the fuel tank on a transmission jack.




7. Operate the transmission jack, then install the fuel tank into the vehicle.





Caution: Refer to Fastener Caution (Fastener Caution).

8. Install the 2 fuel tank bands with the 4 bolts (1, 2, 3, 4) and tighten to 39 Nm (29 lb ft).




9. Install the fuel tank assembly for FWD.
10. Set the fuel tank on a transmission jack.
11. Operate the transmission jack, then install the fuel tank into the vehicle.




12. Install the 2 fuel tank bands with the 4 bolts (1, 2, 3, 4) and tighten to 39 Nm (29 lb ft).





Note: Make sure that the hose clamp (1) is facing in the correct direction when installing.

13. Connect the fuel tank to filler pipe hose to the fuel tank.




14. Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.





Note: Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work. After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.

15. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer (1) up until the claws lock.




16. Connect the breather tube fuel hose (1).




17. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
18. Install the checker onto the pipe.




19. Connect the fuel tank vent hose for Torsion Beam Type Suspension.
20. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
21. Slide the retainer of the fuel tube connector to lock the claws.
22. Install the rear suspension member sub-assembly for Double Wishbone Type Suspension. Refer to Rear Axle Replacement (Except All Wheel Drive and GT) (Service and Repair).
23. Install the charcoal canister assembly. Refer to Evaporative Emission Canister Replacement (Service and Repair).




24. Install the fuel tank protector with the 7 bolts (1-7) for AWD and tighten to 5.5 Nm (49 lb in).




25. Install the fuel tank protector sub-assembly with the 4 bolts (1, 2, 3, 4) for FWD and tighten to 5.5 Nm (49 lb in).




26. Install the parking cables with the 4 bolts (1, 2, 3, 8) or (4, 5, 6, 7) and tighten to 5.4 Nm (48 lb in).
27. Install the propeller with center bearing shaft assembly for AWD. Refer to Propeller Shaft Replacement (Service and Repair)
28. Install the catalytic converter
29. Add fuel.
30. Install the right fuel sender gage assembly for AWD.
31. Install the fuel suction tube assembly.
32. Install the fuel pump gage retainer.
33. Connect the fuel tank vent hose for FWD.
34. Connect the fuel tank main tube sub-assembly.
Warning: Refer to Battery Disconnect Warning (Service Precautions).

35. Connect the cable to the negative battery terminal.
36. Inspect for a fuel leak.
37. Inspect for an exhaust gas leak.
38. Install the rear floor service hole cover.
39. Install the rear seat cushion assembly. Refer to Rear Seat Cushion Replacement (Rear Seat Cushion Replacement).