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.






6. Disconnect connectors from the fuel pump, and move aside the service hole cover.






7. Remove the service hole cover of fuel sub level sensor.






8. Disconnect connectors from the fuel sub level sensor, and move aside the service hole cover.






9. Disconnect the quick connector on the fuel delivery tube.

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









10. Lift up the vehicle.
11. Remove the rear exhaust pipe and muffler.
12. Remove the rear differential.
13. Disconnect the fuel filler hose (A) and evaporation hose (B) from the fuel filler pipe assembly.






14. Disconnect the vent tube from canister.

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










15. Remove the fuel tank protector.






16. Remove the heat shield cover and stopper.






17. 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. 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)






3. Install the heat shield cover and stopper.

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






4. Install the fuel tank protector.

NOTE: Use a new self-locking nut.

Tightening torque:
T1: 9 N.m (0.9 kgf-m, 6.6 ft-lb)
T2: 18 N.m (1.8 kgf-m, 13.3 ft-lb)






5. Connect the vent tube to the canister.

CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
- Make sure that the quick connector is securely connected.

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










6. Install the fuel filler hose (A) and the evaporation hose (B) to the fuel filler pipe assembly.

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










7. Install the rear differential.
8. Install the rear exhaust pipe and muffler.
9. Connect the quick connector of the fuel delivery tube.

CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
- Make sure that the quick connector is securely connected.

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










10. Connect the connector to the fuel sub level sensor.






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






12. Connect the connector to the fuel pump.






13. Install the service hole cover of fuel pump.






14. Install the rear seat cushion.
15. Connect the battery ground terminal.