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 second row seats.
5. Remove the service hole cover of fuel pump.
1. Disconnect the connector (C).
2. Remove the bolt (A).
3. Push the grommet (B) down and remove 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 clip holding the harness.






11. Remove the rear suspension assembly.
12. Disconnect purge hose (A), connector (B) and fuel filler hose (C).






13. 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 when removing.

1. Support the fuel tank with the transmission jack.
2. Remove the fuel tank band that holds the fuel tank.
3. Remove the fuel tank from the vehicle.






INSTALLATION

1. Install the fuel tank to the vehicle.

WARNING: A helper is required to perform this work

1. Lift the fuel tank with the transmission jack.
2. Mount the fuel tank to the vehicle with a jack.
3. Install the fuel tank band that holds the fuel tank.

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






2. Connect purge hose (A), connector (B) and fuel filler hose (C).

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










3. Install the rear suspension assembly.
4. Install the clip that holds the harness.






5. Lower the vehicle.
6. Install the rear wheels.

Tightening torque:
Chromed plated wheel : 150 N.m (15.3 kgf-m, 110.6 ft-lb)
Other than above : 120 N.m (12.2 kgf-m, 88.5 ft-lb)

7. Connect the quick connector of the fuel delivery tube.
8. Install the service hole cover of fuel sub level sensor.






9. Install the service hole cover of fuel pump.
1. Push on the grommet (B) to install it to the service hole cover.
2. Tighten the bolt (A).
3. Connect the connector (C).






10. Install the second seat.
11. Connect the battery ground terminal.
12. Inspect the wheel alignment and adjust if necessary.