Removal of Original Tank

C. REMOVAL OF ORIGINAL TANK

1. Remove 4 bolts, nuts and crossmember No. 5 together with the spare wheel carrier.





2. Remove 4 self-lock nuts securing right and left rear stabilizer brackets to the frame rail, 2 bolts securing rear stabilizer to the rear axle housing and rear stabilizer together with the right and left links and brackets.





3. Remove 4 bolts and fuel hose protector.

4. Loosen clips and disconnect 5 fuel hoses from fuel tube connector.

Note: Since a small amount of fuel remains in the hoses, cover the hoses with a shop towel when disconnecting the hoses, to catch any fuel that may leak out.





5. Disengage 2 front fuel hoses (out of 5) from the body clamps.

6. Loosen both clamps and cut the tankside end of fuel inlet hose to easily disconnect the hose, then disconnect the inlet hose from fuel tank.

7. To prevent the remaining fuel from leaking, use the inlet hole cap fitted onto the new tank to plug the fuel tank inlet hole and fasten with adhesive tape.





8. Loosen the clip and disconnect fuel return hose from fuel tank-side pipe.

9. Loosen the flare nut and disconnect fuel pressure tube from tank-side pipe.

Note: Since a small amount of fuel remains in the hoses, cover the hoses with a shop towel when disconnecting the hoses, to catch any fuel that may leak out.

10. Remove bolt and fuel pipe clamp from body at the front of the tank.





11. Remove 2 bolts and disconnect both right and left rear ends of fuel tank band.





12. Raising the right side of the tank and pulling it to the right, lower the fuel tank from the vehicle.





13. Replace fuel inlet hose and clamps with new ones.

Note: Tighten new clamps slightly so that the clamps do not fall off the inlet hose.