Removal and Replacement
Fuel Tank Removal and InstallationWARNING: When performing the following procedure, be sure to observe Precautions on Fuel System Service to reduce the risk of fire and personal injury.
Removal
1. Relieve fuel pressure.
2. Disconnect negative (-) cable at battery.
3. Remove fuel filler cap.
4. Insert hose of a hand operated pump into fuel filler hose (1) and drain fuel in space "A" as shown in figure.
CAUTION: Do not force pump hose into fuel tank.
5. Hoist vehicle, and remove clamps (2), fuel filler hose (1) and breather hose (3) from fuel filler neck.
6. Remove EVAP canister.
7. Remove exhaust center pipe.
8. Remove propeller shaft (4WD model).
9. Due to absence of fuel tank drain plug, drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
CAUTION:
- Do not force pump hose into fuel tank.
- Never store fuel in an open container due to possibility of fire or explosion.
10. Disconnect quick joints (1) from fuel pipes (2).
11. Support fuel tank (1) with jack (2) and remove its mounting bolts (3).
12. Lower fuel tank a little as to disconnect wire harness at connector (1) and ground wire (2), then remove fuel tank.
Installation
CAUTION:
- When connecting joint, clean outside surfaces of pipe where joint is to be inserted, push joint into pipe till joint lock clicks and check to ensure that pipes are connected securely, or fuel leak may occur.
- Neverlet the fuel hoses touch the wheel speed sensor harness (if equipped).
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 connect fuel pump connector (3), ground wire (4) and clamp wire harness.
Tightening torque
Ground wire bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
3. Install fuel tank to vehicle, and tighten new fuel tank bolts to specified torque.
Tightening torque
Fuel tank bolt (b): 45 N.m (4.6 kg-m, 33.5 lbf-ft)
4. Connect fuel filler hose (1), breather hose (3) and clamps (2) to fuel filler neck (3) as shown in figure, and clamp them securely.
Tightening torque
Fuel tank hose clamp (Non-EVAP-leak-check model) (a): 1.5 N.m (0.15 kg-m, 1.5 lbf-ft)
Fuel tank hose clamp (EVAP leak check model) (b): 3.5 N.m (0.36 kg-m, 2.5 lbf-ft)
5. Connect quick joints (1) to each pipe (2) as shown in figure.
6. Install exhaust center pipe.
7. Install propeller shaft (4WD model).
8. Install EVAP canister.
9. Connect negative (-) cable at battery.
10. With engine stationary, turn ignition switch to ON position and check for fuel leaks.