Fuel Tank Removal and Installation
Special Tools Required
Image Description/Tool Number
14341930.png Wrench, Fuel Sender 07AAA-TBAA100

Flammable - Keep Fire Away

NOTE: Refer to the Fuel and Emissions Systems Service Precautions before disconnecting/connecting the fuel line.

2. Fuel Tank - Drain
1.
NOTE: When installing the fuel tank unit cam lock ring (A) using the fuel sender wrench (B), temporarily set the positioning edge (C) of the fuel tank at the fuel tank unit cam lock ring tabs (D) on the fuel tank unit cam lock ring as shown.

6. Fuel Vent Tube B - Disconnect (KX)

11. Rear Brake Caliper Assembly, Rear Subframe, and Rear Trailing Arm - Remove

NOTE:
Do not disconnect the brake lines and the brake hoses.
Do not twist the brake hose excessively.
1.
Remove the rear subframe with the rear trailing arms, do the following procedures while removing the indicated part(s) from both sides.
The wheel speed sensor/electric parking brake harness bracket bolt (A) and the rear brake hose bracket bolt (B).
The rear upper arm bolt (C), the rear upper arm nut (D), and the rear wheel speed sensor bolt (E).
The rear brake caliper bracket bolts (F).
NOTE: To prevent damage to the rear brake caliper assembly (G), the rear brake hose, the electric parking brake harness, and the rear wheel speed sensor, use a short piece of wire to hang the rear brake caliper assembly from the undercarriage.
The rear damper upper bolts (H).
Disconnect the connector(s) (J).
NOTE: Pay attention to prevent damage to the connector.
Remove the bracket(s) (K).
The rear subframe bolts (L) and the rear trailing arm bolts (M).
NOTE: Place a transmission jack or other support under the rear subframe.

12. Fuel Tank Assembly - Remove
1.
Remove the fuel fill pipe bracket (A), the fuel fill pipe mounting bolt (B), and the ground cable terminal bolt (C).
2.
Place a transmission jack or other support under the fuel tank (A).
3.
Remove the strap (B) and the fuel tank carefully.



Flammable - Keep Fire Away

NOTE:
How to read the torque specifications.
Refer to the Fuel and Emissions Systems Service Precautions before disconnecting/connecting the fuel line.

1. Fuel Tank Unit - Temporarily Install
1.
NOTE: When installing the fuel tank unit cam lock ring (A) using the fuel sender wrench (B), temporarily set the positioning edge (C) of the fuel tank at the fuel tank unit cam lock ring tabs (D) on the fuel tank unit cam lock ring as shown.

2. Fuel Tank Assembly - Install (Except 5-door)
1.
KA/KC/KL: Tape the fuel tank vapor recirculation tube (A) as shown.
2.
Place a transmission jack under the fuel tank (B) and carefully raise the fuel tank into position.
3.
Install the fuel tank and the strap (C).
NOTE: Tighten the fuel tank mounting bolts and the strap mounting bolts in the following procedure.
Loosely install the fuel tank mounting bolts (D).
Tighten the fuel tank mounting bolts to the specified torque in the numbered sequence shown.
Loosely install the strap mounting bolts (E).
Tighten the strap mounting bolts to the specified torque in the numbered sequence shown.
4.
Install the fuel fill pipe bracket (A), the fuel fill pipe mounting bolt (B), and the ground cable terminal bolt (C).

3. Fuel Tank Assembly - Install (5-door)
1.
Tape the fuel tank vapor recirculation tube (A) as shown.
2.
Place a transmission jack under the fuel tank (B) and carefully raise the fuel tank into position.
3.
Install the fuel tank and the strap (C).
NOTE: Tighten the fuel tank mounting bolts and the strap mounting bolts in the following procedure.
Loosely install the right side fuel tank mounting bolt (D).
Tighten the left side fuel tank mounting bolt (E) to 24 N·m (2.4 kgf·m, 18 lbf·ft).
Tighten the right side fuel tank mounting bolt to 24 N·m (2.4 kgf·m, 18 lbf·ft).
Loosely install the front side strap mounting bolt (F).
Tighten the rear side strap mounting bolt (G) to 38 N·m (3.9 kgf·m, 28 lbf·ft).
Tighten the front side strap mounting bolt to 38 N·m (3.9 kgf·m, 28 lbf·ft).
4.
Install the fuel fill pipe bracket (A), the fuel fill pipe mounting bolt (B), and the ground cable terminal bolt (C).

4. Rear Subframe, Rear Trailing Arm, and Rear Brake Caliper Assembly - Install
1.
Install the rear subframe with the rear trailing arms, do the following procedures while installing the indicated part(s) from both sides.


9. Fuel Vent Tube B - Connect (KX)
NOTE: Make sure the hose clamps are properly positioned and tightened.
1.
Replace the new fuel tank unit cam lock ring (A) and the new O-ring (B), do the following procedures.
Refer to the "Fuel Tank Unit Cam Lock Ring - Unlock" on the Fuel Tank Unit Removal and Installation.
2.
KA/KC/KL: Connect the fuel vent tube (C) and fuel tank vapor recirculation tube (D), do the following procedures.
Refer to the "Fuel Vent Tube and Fuel Tank Vapor Recirculation Tube - Connect (KA/KC/KL)" on the Fuel Tank Unit Removal and Installation.
3.
Lock the fuel tank unit cam lock ring, do the following procedures.
Refer to the "Fuel Tank Unit Cam Lock Ring - Lock" on the Fuel Tank Unit Removal and Installation.

14. Fuel Leak - Check

KA/KC/KL

KX

2.
Connect the connector (B).
3.
Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurized. Repeat this two or three times, then check for fuel leakage.
4.
KA/KC/KL: If equipped, install the fuel connector cover (C).
5.
Install the access panel (D) to the floor.