Removal and Replacement

Fuel Tank

REMOVAL

WARNING: Place "NO OPEN FLAMES" signs near the working area

CAUTION: Be careful not to spill fuel.

1. Set the vehicle on a lift.
2. Release the fuel pressure.
3. Drain fuel from fuel tank.
4. Disconnect the ground cable from the battery.






5. Remove the rear seat cushion.
6. Remove the service hole cover of fuel pump.
1. Disconnect fuel pump connector (A), and remove clip (B).
2. Remove the bolt (C).
3. Push the grommet (D) down and remove the service hole cover.






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






8. Disconnect tine quick connector on tine fuel delivery tube (A).






9. Remove the rear wheels.
10. Lift up the vehicle.
11. Remove the rear ABS wheel speed sensor from the rear housing.






12. Remove the bolt holding the rear brake hose bracket.






13. Remove the rear brake caliper and tie it to the body side of the vehicle.






14. Remove the parking brake cable from the parking brake assembly.
15. Remove the rear exhaust pipe.
16. Remove the propeller shaft.
17. Remove the heat shield cover and fuel tank protector.
18. Disconnect the connector from the rear ABS wheel speed sensor.






19. Remove the bolts securing the parking brake cable clamp.






20. Disconnect drain hose (B) from the canister drain connector (A).






21. Disconnect the connector, remove the nuts, and then remove the rear vehicle height sensor, (models with auto headlight beam leveler, left side only)






22. Remove the rear suspension assembly.

WARNING: A helper is required to perform this work.

1. Support the rear differential with the transmission jack.
2. Remove the bolts which hold the rear shock absorber to the rear suspension arm.






3. Remove the bolts which secure the rear suspension assembly to the body.






4. Remove the rear suspension assembly.

23. Disconnect evaporation hose (B) from connector (A).






24. Disconnect tine quick connector of tine evaporation hose from tine evaporation pipe as shown in tine figure.









25. Disconnect tine fuel filler hose (A) and evaporation hose (B) from the fuel filler pipe assembly.






26. 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 when removing.






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. Securely insert the fuel filler hose (A) and evaporation hose (B) into the specified position, then attach the clamp and clip as shown in the figure.






3. Connect the quick connector of the evaporation hose to the evaporation pipe.

CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean seal surface of pipe.
- When connecting the quick connector, insert the pipe all the way in securely, then operate the push lock.
- If it is not possible to perform the push lock operation of the retainer, recheck whether the pipe is securely inserted.
- Confirm that the quick connector is securely connected.









4. Connect evaporation hose (B) to connector (A).






5. Tighten the fuel tank band bolts in the order shown in the figure.






6. Install the rear suspension assembly.

WARNING: A helper is required to perform this work.

1. Support the rear differential with the transmission jack.
2. Support the rear suspension assembly, and tighten the bolts which secure the rear suspension assembly to the body.






3. Tighten the bolts which hold the rear shock absorber to the rear suspension arm.






7. Install the rear vehicle height sensor, (models with auto headlight beam leveler, left side only)

Tightening torque: 7.5 N.m (0.8 kgf.m, 5.5 ft.lb)

8. Install the rear vehicle height sensor connector, (models with auto headlight beam leveler, left side only)
9. Connect drain hose (B) to canister drain connector (A).






10. Tighten the bolts holding the parking brake cable clamp.






11. Connect the connector to the rear ABS wheel speed sensor.






12. Install the heat shield cover.

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

13. Install the fuel tank protector.

Tightening torque:
Nut: 9 N.m (0.9 kgf.m, 6.6 ft.lb)
Bolt: 18 N.m (1.8 kgf.m, 13.3 ft.lb)

14. Install the propeller shaft.
15. Install the rear exhaust pipe.
16. Lower the vehicle.
17. Connect the parking brake cable to the parking brake assembly.
18. Install the rear brake caliper.
19. Tighten the bolts which hold the rear brake hose bracket.






20. Attach the rear ABS vehicle speed sensor to the rear housing.






21. Install the rear wheels.

Tightening torque: 100 N.m (10.2 kgf.m, 73.8 ft.lb)

22. Connect quick connector of the fuel delivery tube (A).






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






24. Attach the service hole cover of the fuel pump, and secure the connector and clip.






25. Install the rear seat cushion.
26. Install the fuse of fuel pump to main fuse box.
27. Connect the ground cable to the battery.






28. Inspect the wheel alignment and adjust if necessary.
29. Re-initialize the auto headlight beam leveler system.