Removal and Replacement

Fuel Tank

REMOVAL

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 of fuel delivery tube (A) and fuel return tube (B).






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. Remove the parking brake cable clamp from the body.






19. Remove the rear suspension assembly.

WARNING: A helper is required to perform this work.

1. Support the rear differential with the 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. Disconnect evaporation hose (B) from connector (A).






21. Disconnect the quick connector of the evaporation hose from the evaporation pipe.

NOTE: Disconnect the quick connector as shown in the figure.









22. Disconnect the fuel filler hose (A) and evaporation hose (B).






23. 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. Securely insert the fuel filler hose (A) and evaporation hose (B) until the hose end contacts the spool, then attach the clamp or clip as shown in the figure.

Tightening torque: 2.5 N.m (0.3 kgf.m, 1.8 ft.lb)









3. 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.









4. Connect evaporation hose (B) to connector (A).






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 rear suspension assembly.

WARNING: A helper is required to perform this work.

1. Support the rear differential with the 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)






7. Install the parking brake cable clamp to the body.

Tightening torque: 18 N.m (1.8 kgf.m, 13.3 ft.lb)






8. Connect the connector to the rear ABS wheel speed sensor.






9. Install the heat shield cover.

Tightening torque: 18 N.m (1.8 kgf.m, 13.3 ft.lb)

10. Install the fuel tank protector.

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)

11. Install the propeller shaft.
12. Install the rear exhaust pipe and muffler.
13. Lower the vehicle.
14. Connect the parking brake cable to the parking brake assembly.
15. Install the rear disc brake assembly.

Tightening torque: 66 N.m (6.7 kgf.m, 48.7 ft.lb)






16. Install the rear brake hose bracket to the rear housing.

Tightening torque: 33 N.m (3.4 kgf.m, 24.3 ft.lb)






17. 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)






18. Install the rear wheels.

Tightening torque: 100 N.m (10.2 kgf.m, 73.8 ft.lb)

19. Connect the quick connector of fuel delivery tube (A) and fuel return tube (B).

NOTE: When connecting, be careful not to reverse the delivery side and return side.






20. Install the service hole cover of fuel sub level sensor.






21. Attach the service hole cover of the fuel pump, and attach the connector and clip.






22. Install the rear seat cushion.
23. Connect the battery ground terminal.






24. Inspect the wheel alignment and adjust if necessary.