Fuel Tank Replacement

Fuel Tank Replacement

Removal

1. Relieve the fuel pressure.
2. Drain the fuel tank.
3. Loosen the rear wheel nuts slightly, then raise the vehicle, and make sure it is securely supported. Remove the rear wheels.
4. Release the parking brake.




5. SULEV model: Remove the fuel tank covers (A).
6. Remove the exhaust muffler.




7. Non-SULEV model: Disconnect the fuel fill neck tube (A) and breather hose (B).




8. SULEV model: Disconnect the fuel fill neck tube (A), fuel tank vapor recirculation tube (B), and fuel tank vapor signal tube (C)




9. Disconnect the vapor line (A) from the EVAP canister (B). Then disconnect the fuel line (C)




10. Disconnect the wheel sensor 2P connector (A).




11. If the vehicle has rear drum brakes, go to step 14. If it has rear disc brakes, remove the clip (A), parking brake cable (B), two caliper bolts (C), and caliper body (D).




12. Remove the brake hose bracket (E).




13. Hook the caliper body (A) on the damper spring (B), then go to step 17.




14. Disconnect the brake line (A) and the brake hose clip (B).




15. Remove the bolts (A) from the brake plate (B).




16. Remove the parking brake cable (A).




17. Remove the flange bolt (A).




18. Remove the parking brake cable bracket (A).




19. Remove the heat shield (A). Place a jack or support under the suspension subframe. Remove the mounting bolts (B). Remove the rear suspension subframe.




20. Remove the bolts (A) and the fuel tank straps (B).
21. Lift the fuel tank out of the subframe.

Installation




1. Install the tank straps (A), and tighten the bolts (B).




2. Place a jack or support under the rear suspension subframe. Install the rear suspension subframe, aligning the pins (A) with the holes in the rear suspension subframe.
3. Install the remaining parts in the reverse order of removal.
4. If equipped with drum brakes, bleed the brake system after installing the brake hose. If not, go to step 5.
5. After installation, check a the wheel alignment.