Fuel Tank Removal and Installation
REMOVAL1. REMOVE REAR SEAT CUSHION ASSEMBLY
2. REMOVE REAR FLOOR SERVICE HOLE COVER
3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
4. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
5. DRAIN FUEL
6. REMOVE CENTER EXHAUST PIPE ASSEMBLY
7. REMOVE NO. 1 FUEL TANK PROTECTOR
a. Remove the 5 bolts and fuel tank protector.
8. REMOVE CANISTER ASSEMBLY
9. REMOVE REAR SUSPENSION BRACE LOWER LH
a. Remove the 3 bolts and rear suspension brace lower.
10. REMOVE REAR SUSPENSION BRACE LOWER RH
a. Remove the 2 bolts and rear suspension brace lower.
11. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel tank main tube.
1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and push it down as shown in the illustration.
2. Pull the fuel tank main tube out of the pipe.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tank main tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
b. Disconnect the fuel tank breather tube from the fuel tank.
1. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that the seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
c. Separate the claw fitting, then remove the fuel hose protector.
d. Loosen the hose clamp bolt, then disconnect the fuel tank to filler pipe hose.
e. Hold the fuel tank using a transmission jack.
f. Remove the 4 bolts and 2 fuel tank bands.
g. Operate the transmission jack, then remove the fuel tank.
INSTALLATION
1. INSTALL FUEL TANK ASSEMBLY
a. Set the fuel tank onto a transmission jack.
b. Operate the transmission jack, then install the fuel tank into the vehicle.
c. Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
d. Connect the fuel tank to filler pipe hose to the fuel tank, then tighten the hose clamp.
NOTE: Make sure that the mark and hose clamp are at the correct angle when installing.
e. Install the fuel hose protector.
f. Connect the fuel tank breather tube to the fuel tank.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube breather tube to the pipe.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
g. Connect the fuel tank main tube.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector until the it comes into contact with the seat to connect the fuel tank main tube to the pipe. Then push the retainer up until the claws lock.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling the fuel tube connector and pipe.
2. INSTALL REAR SUSPENSION BRACE LOWER RH
a. Install the rear suspension brace lower with the 2 bolts.
Torque: 63.5 N.m (645 kgf.cm, 47 ft.lbf)
3. INSTALL REAR SUSPENSION BRACE LOWER LH
a. Install the rear suspension brace lower with the 3 bolts.
Torque: 63.5 N.m (645 kgf.cm, 47 ft.lbf)
4. INSTALL CANISTER ASSEMBLY
5. INSTALL NO. 1 FUEL TANK PROTECTOR
a. Install the No. 1 fuel tank protector with the 5 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
6. INSTALL CENTER EXHAUST PIPE ASSEMBLY
7. ADD FUEL
8. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
9. INSTALL REAR FLOOR SERVICE HOLE COVER
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. PERFORM INITIALIZATION
a. Perform initialization
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
12. CHECK FOR FUEL LEAKS
13. INSTALL REAR SEAT CUSHION ASSEMBLY