Fuel Tank Removal and Installation

Fuel Tank Removal and Installation

WARNING:

There is a risk of fire or explosion if the drained fuel is stored in an inappropriate container.

Avoid using an open container to hold the fuel.

Removal

1) Relieve fuel pressure. Service and Repair
2) Disconnect negative (-) cable at battery.
3) Remove fuel filler cap.
4) Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel in space "A" as shown in figure.

NOTE:
The hose of the hand-operated pump could damage the fuel tank inlet valve if too much force is used when inserting it into the fuel filler hose.

Do not apply too strong a force when inserting the pump hose into the fuel filler hose.









5) Hoist vehicle, and remove clamps (2), fuel filler hose (1) and breather hose (3) from fuel filler neck.





6) Remove EVAP canister. EVAP Canister Removal and Installation
7) Remove exhaust center pipe. Exhaust Pipe and Muffler Removal and Installation.
8) Remove propeller shaft (4WD model). Propeller Shaft Assembly Removal and Installation
9) Disconnect quick joints (1) from fuel pipes (2). Fuel Hose Disconnecting and Reconnecting






10) Support fuel tank (1) with jack (2) and remove its mounting bolts (3).





11) Lower fuel tank a little as to disconnect wire harness at connector (1) and ground wire (2), then remove fuel tank.






Installation

Fuel Tank Inspection

Fuel Tank Purging Procedure

WARNING:

Failure to take proper precautions when reinstalling the fuel tank connections can result in fuel leakage or damage.

- Clean the outside surface of the pipe where each quick joint is to be installed, push the pipe into the joint until the joint lock clicks, and then confirm that the pipe is connected securely.
- Secure the fuel hoses and the wheel speed sensor harness (if equipped) so that they will not come in contact with each other.

1) If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.
2) Raise fuel tank (1) with jack (2) and connect fuel pump connector (3), ground wire (4) and clamp wire harness.

Tightening torque
Ground wire bolt (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)

3) Install fuel tank to vehicle, and tighten new fuel tank bolts to specified torque.

Tightening torque
Fuel tank bolt (b): 45 Nm (4.6 kgf-m, 33.5 lbf-ft)





4) Connect fuel filler hose (1), breather hose (3) and clamps (2) to fuel filler neck (3) as shown in figure, and clamp them securely.

Tightening torque
Fuel tank hose clamp (Non-EVAP-leak-check model) (a): 1.5 Nm (0.15 kgf-m, 1.5 lbf-ft)
Fuel tank hose clamp (EVAP leak check model) (b): 3.5 Nm (0.36 kgf-m, 2.5 lbf-ft)









5) Connect quick joints (1) to each pipe (2) as shown in figure.





6) Install exhaust center pipe. Exhaust Pipe and Muffler Removal and Installation
7) Install propeller shaft (4WD model). Propeller Shaft Assembly Removal and Installation
8) Install EVAP canister. EVAP Canister Removal and Installation
9) Connect negative (-) cable at battery.
10) With engine stationary, turn ignition switch to ON position and check for fuel leaks. Fuel Leakage Check Procedure