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. Disconnect the ground cable from battery.
3. Drain fuel.
4. Remove the second row seats.
5. Remove the service hole cover of fuel pump.
1. Disconnect the connector (C).
2. Remove the bolt (A).
3. Push the grommet (B) down and remove service hole cover.






6. Remove the service hole cover of fuel sub level sensor.






7. Disconnect the quick connector on the fuel delivery hose.







8. Remove the rear wheels.
9. Lift up the vehicle.
10. Remove the clip holding the harness.







11. Remove the rear suspension assembly.
12. Disconnect evaporation hose (A), connector (B) and fuel filler hose (C).






13. Remove the fuel tank from the vehicle.

WARNING:
- A helper is required to perform this work.
- The 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.

1. Support the fuel tank with the transmission jack.
2. Remove the fuel tank band that holds the fuel tank.
3. Remove the fuel tank from the vehicle.






INSTALLATION

1. Install the fuel tank to the vehicle.

WARNING: A helper is required to perform this work.

1. Lift the fuel tank with the transmission jack.
2. Mount the fuel tank to the vehicle with a jack.
3. Install the fuel tank band that holds the fuel tank.






2. Connect evaporation hose (A), connector (B) and fuel filler hose (C).






3. Install the rear suspension assembly.
4. Install the clip that holds the harness.






5. Lower the vehicle.
6. Install the rear wheels.

Tightening torque:
Chromed plated wheel: 150 N.m (15.3 kgf.m, 110.6 ft.lb)
Other than above: 120 N.m (12.2 kgf.m, 88.5 ft.lb)

7. Connect the quick connector of the fuel delivery hose.
8. Install the service hole cover of fuel sub level sensor.






9. Install the service hole cover of fuel pump.
1. Push on the grommet (B) to install it to the service hole cover.
2. Tighten the bolt (A).
3. Connect the connector (C).






10. Install the second seat.
11. Install the fuse of fuel pump to the main fuse box.
12. Connect the ground cable to battery.