Removal and Replacement
Fuel TankREMOVAL
WARNING: Place "NO OPEN FLAMES" signs near the working area.
CAUTION: Be careful not to spill fuel.
1. Release the fuel pressure.
2. Drain fuel.
3. Disconnect the ground cable from battery.
4. Remove the rear seat cushion.
5. Remove the service hole cover of fuel pump.
1. Disconnect fuel pump connector (A), and remove clip (B).
2. Remove the screw (C).
3. Push the grommet (D) down and remove the service hole cover.
6. Remove the service hole cover of fuel sub level sensor.
7. Disconnect the quick connector on the fuel delivery tube.
8. Remove the rear wheels.
9. Lift up the vehicle.
10 Remove the rear ABS wheel speed sensor from the rear housing.
11. Remove the rear brake hose bracket from rear housing.
12. Remove the rear disc brake assembly and tie it to the body side of the vehicle.
13. Remove the parking brake cable from parking brake assembly.
14. Remove the rear exhaust pipe and muffler.
15. Remove the propeller shaft.
16. Remove the heat shield cover and fuel tank protector.
17. Disconnect the connector from the rear ABS wheel speed sensor.
18. Disconnect the connector (A) from the rear vehicle height sensor, and remove the rear vehicle height sensor. (model with auto headlight beam leveler, left side only)
19. Remove the rear suspension assembly.
WARNING: A helper is required to perform this work.
1. Support the rear suspension assembly with a transmission jack.
2. Remove the bolt and nut which secures rear shock absorber to rear suspension arm.
3. Remove the bolts which secure the rear suspension assembly to the body.
4. Remove the rear suspension assembly.
20. Remove the parking brake cable clamp from the body.
21. Disconnect the evaporation hose from the fuel tank.
22. Disconnect the fuel filler hose from the fuel filler pipe assembly.
23. Disconnect the quick connector of the evaporation hose from the evaporation pipe.
NOTE: Disconnect the quick connector as shown in the figure.
24. Support the fuel tank with a transmission jack, remove the bolts from the fuel tank band, and remove the fuel tank from the vehicle.
WARNING:
- A helper is required to perform this work.
- Fuel may remain in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop the fuel tank.
INSTALLATION
1. Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.
WARNING: A helper is required to perform this work.
2. Connect the quick connector of the evaporation hose to the evaporation pipe.
CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
- When connecting the quick connector, securely insert the pipe all the way before locking the retainer.
- When it is difficult to lock the retainer, make sure that the pipe is securely inserted.
- Make sure that the quick connector is securely connected.
3. Securely insert the fuel filler hose to the spool, and then install a clamp or clip as shown.
Tightening torque: 2.5 N.m (0.3 kgf.m, 1.8 ft.lb)
4. Connect the evaporation hose to fuel tank.
5. Tighten the bolts of the fuel tank band in the order shown in the figure.
Tightening torque: 33 N.m (3.4 kgf.m, 24.3 ft.lb)
6. Install the parking brake cable clamp to the body.
Tightening torque: 18 N.m (1.8 kgf.m, 13.3 ft.lb)
7. Install the rear suspension assembly.
WARNING: A helper is required to perform this work.
1. Support the rear suspension assembly with a transmission jack.
2. Support the rear suspension assembly and install the rear suspension assembly to the body.
Tightening torque:
T1: 70 N.m (7.1 kgf.m, 51.6 ft.lb)
T2: 145 N.m (14.8 kgf.m, 106.9 ft.lb)
3. Install the rear shock absorber to the rear suspension arm.
NOTE: Use a new self-locking nut.
Tightening torque: 120 N.m (12.2 kgf.m, 88.5 ft.lb)
8. Install the rear vehicle height sensor and connect the connector (A) to the rear vehicle height sensor. (model with auto headlight beam leveler, left side only)
Tightening torque: 7.5 N.m (0.8 kgf.m, 5.5 ft.lb)
9. Connect the connector to the rear ABS wheel speed sensor.
10 Install the heat shield cover.
Tightening torque: 18 N.m (1.8 kgf.m, 13.3 ft.lb)
11. Install the fuel tank protector.
NOTE: Use a new self-locking nut.
Tightening torque:
Nut: 9 N.m (0.9 kgf.m, 6.6 ft.lb)
Bolt: 18 N.m (1.8 kgf.m, 13.3 ft.lb)
12. Install the propeller shaft.
13. Install the rear exhaust pipe and muffler.
14. Lower the vehicle.
15. Connect the parking brake cable to the parking brake assembly.
16. Install the rear disc brake assembly.
Tightening torque: 66 N.m (6.7 kgf.m, 48.7 ft.lb)
17. Install the rear brake hose bracket to the rear housing.
Tightening torque: 33 N.m (3.4 kgf.m, 24.3 ft.lb)
18. Attach the rear ABS wheel speed sensor to the rear housing.
Tightening torque: 7.5 N.m (0.8 kgf.m, 5.5 ft.lb)
19. Install the rear wheels.
Tightening torque: 100 N.m (10.2 kgf.m, 73.8 ft.lb)
20. Connect the quick connector of the fuel delivery tube.
21. Install the service hole cover of fuel sub level sensor.
22. Attach the service hole cover of the fuel pump, and attach the connector and clip.
23. Install the rear seat cushion.
24. Connect the battery ground terminal.
25. Inspect the wheel alignment and adjust if necessary.
26. Perform reinitialization of the auto headlight beam leveler system.