Removal and Replacement

Fuel Tank Removal and Installation

CAUTION: When servicing fuel tank, it should be treated carefully. Pay attention not to contact with sharp edges or hot surfaces. In addition, fuel tank should not be dropped since fuel tank, fuel pump and other components can be damaged by impact. If dropped, all components should be replaced because there is a risk of damage.

Removal
1. Relieve fuel pressure in fuel feed line.
2. Disconnect negative (-) cable from battery.
3. Hoist vehicle.
4. Remove exhaust pipe No.2.
5. For 4WD model, remove propeller shaft.
6. With cable connected, detach parking brake cable clamp from body.
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.
8. Disconnect breather hose (1) and EVAP canister hose (2).






9. Disconnect fuel feed pipe (1).






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






Installation

NOTE: If parts have been removed from fuel tank, install them before installing fuel tank to vehicle.

1. Raise fuel tank (1) with jack (2) and then install fuel tank to vehicle.

Tightening torque
Fuel tank bolt (a): 45 N.m (4.6 kg-m, 33.5 lbf-ft)






2. Connect fuel feed pipe (fuel pump side) (1) to fuel feed pipe (body side) (2), and clamp them securely.

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






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






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






6. Install parking brake cable clamp to vehicle body.
7. For 4WD model, install propeller shaft.
8. Install exhaust pipe No.2.
9. Connect negative (-) cable to battery.
10. With engine stationary, ignition mode of keyless push start system in "ON" and check for fuel leaks.