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.
4. Disconnect the ground cable from battery.






5. Remove the rear seat cushion.
6. Remove the service hole cover of fuel pump.
1. Disconnect connector (A) of the fuel pump, and remove clip (B).
2. Remove the screw (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 the quick connector of fuel delivery tube (A) and fuel return tube (B).






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 rear brake hose bracket from rear housing.






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






14. Remove the parking brake cable from parking brake assembly.
15. Remove the rear exhaust pipe and muffler.
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 parking brake cable clamp from the body.






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






21. Disconnect the connector, and 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 bolt and nut which secure rear shock absorber to 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 the quick connector of the evaporation hose from the evaporation pipe.

NOTE: Disconnect the quick connector as shown in the figure.






25. Disconnect the fuel filler hose (A) and evaporation hose (B).






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 spool, then attach the clamp or 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.
- Make sure that the quick connector is securely connected.






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






5. Tighten the bolts of the fuel tank band 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. While supporting the rear suspension assembly, install the rear suspension assembly to the body.






3. Install the rear shock absorber to the rear suspension arm.

NOTE: Use a new self-locking nut.






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






8. Connect canister drain hose (B) to canister drain connector (A).






9. Install the parking brake cable clamp to the body.






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






11. Install the heat shield cover.

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

12. 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)

13. Install the propeller shaft.
14. Install the rear exhaust pipe and muffler.
15. Lower the vehicle.
16. Connect the parking brake cable to the parking brake assembly.
17. Install the rear disc brake assembly.






18. Install the rear brake hose bracket to the rear housing.






19. Install the rear ABS wheel speed sensor to the rear housing.






20. Install the rear wheels.

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

21. Connect the quick connector of fuel delivery tube (A) and fuel return tube (B).

NOTE: When connecting, be careful not to reverse the delivery side and return side.






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






23. Install the service hole cover of the fuel pump, and install the connector and clip.






24. Install the rear seat cushion.
25. Connect the ground cable to battery.






26. Inspect the wheel alignment and adjust if necessary.
27. Perform reinitialization of the auto headlight beam leveler system. (model with auto headlight beam leveler)