Removal and Replacement

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FUEL TANK REMOVAL/INSTALLATION - HYBRID

Removal/Installation

WARNING:Do not smoke, or carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING:When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING:Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

2. Drain the fuel tank. See Procedures.

3. Remove the exhaust muffler and resonator. See - Service and Repair.

All wheel drive (AWD) vehicles

1. Remove the rear driveshaft. See Removal and Replacement.

All vehicles

1. Release the clamp and remove the fuel tank filler pipe hose from the fuel tank.

- To install, tighten to 4 Nm {0.4 kgf-m, 35 in-lbf}.

2. Position a suitable lifting device under the fuel tank.

3. Detach the parking brake cable pin-type retainer from the LH fuel tank strap.

4. Detach the wire harness pin-type retainer from the LH fuel tank strap.

5. Remove the 2 bolts and position the 2 fuel tank straps aside.

- To install, tighten to 55 Nm {5.6 kgf-m, 41 ft-lbf}.

6. Partially lower the fuel tank enough to access and disconnect the fuel vapor tube assembly-to-fuel tank quick connect coupling. See - Quick Release Coupling - Double Locking.

7. Completely lower and remove the fuel tank from the vehicle.

8. To install, reverse the removal procedure.