Removal and Replacement

Fuel Tank

REMOVAL

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

CAUTION: Be careful not to spill fuel.

1. Release the fuel pressure.
2. Drain fuel.
3. Disconnect the ground cable from battery.
4. Remove the rear seat cushion.
5. Remove the clips (A) and seat cushion hooks (B), and turn over the floor mat (C).






6. Remove the service hole cover of fuel pump.
1. Disconnect the fuel cord connector (A), and remove the 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 on the 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 rear ABS wheel speed sensor harness bracket from the upper arm.






13. Remove the rear brake hose bracket from rear housing.






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






15. Remove the parking brake cable from parking brake assembly.
16. Remove the rear exhaust pipe and muffler.
17. Remove the heat shield cover.






18. Remove the propeller shaft.
19. Remove the clip (A) securing the fuel tank protector and heat shield cover.
20. Remove the bolts (B) and nuts (C) securing the fuel tank protector, and remove the fuel tank protector.






21. Remove the bolts and nuts securing the heat shield cover and remove the heat shield cover.






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 the air vent hose from the fuel tank.






24. Disconnect the quick connector of the circulate tube from evaporation pipe.

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






25. Disconnect the fuel filler hose (A) and circulate 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 circulate hose (B) to the spool, then attach the clamp or clip as shown in the figure.






3. Connect the quick connector of the circulate tube to the evaporation pipe as shown in the figure.

CAUTION:
- Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
- Make sure that the quick connector is securely connected.






4. Connect the air vent hose to fuel tank.






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 heat shield cover.






8. Install the bolts (B) and nuts (C) securing the fuel tank protector and install the clip (A) securing the fuel tank protector and heat shield cover.






9. Install the propeller shaft.
10. Install the heat shield cover.






11. Install the rear exhaust pipe and muffler.
12. Lower the vehicle.
13. Connect the parking brake cable to the parking brake assembly.
14. Install the rear disc brake assembly.






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






16. Install the rear ABS wheel speed sensor harness bracket to the upper arm.






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






18. Install the rear wheels.

Tightening torque: 120 N.m (12.2 kgf.m, 88.5 ft.lb)

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






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






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






22. Set the floor mat (C), and install clips (A) and seat cushion hooks (B).






23. Install the rear seat cushion.
24. Connect the ground cable to battery.
25. Inspect the wheel alignment and adjust if necessary.