Removal and Replacement
Fuel Tank Removal and InstallationWARNING: Before starting the following procedure, be sure to observe Precautions on Fuel System Service in order to reduce the risk or fire and personal injury.
Removal
1. Relieve fuel pressure in fuel feed line according to Fuel Pressure Relief Procedure.
2. Disconnect negative (-) cable at battery.
3. Hoist vehicle.
4. Remove exhaust center pipe.
5. Remove rear propeller shaft referring to Propeller Shaft Removal and Installation
6. With cable connected, detach parking brake cable clamp from fuel tank cover referring to Parking Brake Cable Location
7. Disconnect fuel filler hose (2) and breather hose from filler neck referring to Fuel Tank Inlet Valve Removal and Installation.
8. Disconnect fuel pump connector (1).
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, or pump hose may damage fuel tank inlet valve.
- Never store fuel in an open container due to possibility of fire or explosion.
10. Disconnect fuel hoses (2) and EVAP canister hose (1) from each pipe referring to Fuel Hose Disconnecting and Reconnecting.
11. Support fuel tank (1) with jack (2) and remove fuel tank.
Installation
Reference: Fuel Tank Inspection
Reference: Fuel Tank Purging Procedure
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.
- Never let the fuel hoses touch the ABS 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, and connect connectors of fuel pump and sub fuel level gauge and clamp wire harness.
3. Install fuel tank to vehicle, and tighten new fuel tank bolts to specified torque.
Tightening torque
Fuel tank bolt (a): 45 N.m (4.5 kg.m, 32.5 lbf.ft)
4. Connect fuel filler hose (1) and breather hose to filler neck as shown in figure, and clamp them securely.
For proper installation, refer to Fuel Hose Disconnecting and Reconnecting.
Tightening torque
Fuel filler hose clamp (a): 4 N.m (0.4 kg.m, 3.0 lbf.ft)
5. Connect fuel pump connector (2).
6. Connect fuel hoses (1) and EVAP canister hose (2) to each pipe as shown in figure, and clamp them securely referring to Fuel Hose Disconnecting and Reconnecting.
7. Install parking brake cable clamp to fuel tank cover referring to Parking Brake Cable Location
8. Install rear propeller shaft referring to Propeller Shaft Removal and Installation
9. Install exhaust center pipe referring to Exhaust System Components.
10. Connect negative (-) cable at battery.
11. With engine OFF, turn ignition switch to ON position and check for fuel leaks.