Fuel Tank Removal and Installation

Fuel Tank Removal and Installation

Removal

1) Relieve fuel pressure in fuel feed line. Service and Repair
2) Disconnect negative (-) cable from battery.
3) Hoist vehicle.
4) Remove exhaust pipe No.2. Exhaust System Components
5) For 4WD model, remove propeller shaft. Propeller Shaft Assembly Removal and Installation
6) With cable connected, detach parking brake cable clamp from body. Locations
7) Remove fuel filler hose from fuel tank referring to Step 1) to Step 4) of "Removal" under Fuel Tank Inlet Valve Removal and Installation Fuel Tank Inlet Valve Removal and Installation.
8) Disconnect breather hose (1) and EVAP canister hose (2).





9) Disconnect fuel feed pipe (1). Fuel Hose Disconnecting and Reconnecting





10) Support fuel tank (1) with jack (2) and remove fuel tank.






Installation

Fuel Tank Inspection

Fuel Tank Flushing 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.

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 then install fuel tank to vehicle.

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





3) Connect fuel feed pipe (fuel pump side) (1) to fuel feed pipe (body side) (2), and clamp them securely. Fuel Hose Disconnecting and Reconnecting

NOTE:
Clearance "a" between quick joint (3) and parking brake cable clamp (4) should be more than 15 mm.





4) Connect breather hose (1) and EVAP canister hose (2).





5) Install fuel filler hose (1) to fuel tank and secure it with clamps (2) referring to Fuel Hose Disconnecting and Reconnecting Fuel Hose Disconnecting and Reconnecting.
6) Connect fuel tank harness connector (3).





7) Install parking brake cable clamp to vehicle body. Locations
8) For 4WD model, install propeller shaft. Propeller Shaft Assembly Removal and Installation
9) Install exhaust pipe No.2. Exhaust System Components
10) Connect negative (-) cable to battery.
11) With engine stationary, ignition mode of keyless push start system in "ON" and check for fuel leaks. Fuel Leakage Check Procedure