Tank Assembly

REMOVAL & INSTALLATION

Mounted Behind Rear Seat

1. Disconnect the ground cable from the negative (-) terminal of the battery.
2. Remove the rear seat and luggage shelf.
3. Disconnect the gas line running to the fuel pump and drain the gas tank. Removing the gas filler cap will enable the gas to drain faster.

   CAUTION
   When draining the gas tank try to avoid making sparks, also avoid smoking or open flames! Use a safe container to store the gas.

   Plug the gas line with a bolt (8mm) to prevent drain back from the fuel pump.

4. Disconnect the evaporation hose from the tank pipes.
5. Remove the hardboard from the trunk.
6. Loosen the clamps holding the filler hose to the filler pipe. Remove the filler hose.
7. Disconnect the wiring harness from the fuel sending unit.
8. Remove the bolts from the right and left side of the fuel tank. Remove the tank by pulling it out of the brackets.
9. During installation, be sure to connect the filler hose after the tank has been mounted, to prevent leakage at the connection. Be careful not to kink hoses or overtighten fittings when reconnecting.

Mounted Under Vehicle

1. Disconnect the ground cable from the negative (-) terminal of the battery.
2. Block the front wheels of the vehicle. Raise the rear of the vehicle.

   Fig. 1: Disconnect the fuel tank sending unit wiring harness

   Fig. 2: Remove the drain plug to drain the fuel tank

   WARNING
   Refer to the correct jacking points, as mentioned in earlier Section 1. Make sure to support the vehicle with stands.

3. Remove the right rear wheel.
4. Disconnect the fuel tank sending unit wiring harness.
5. Drain the gas tank, by removing the drain plug, or disconnecting the fuel feed line to the fuel pump.

   CAUTION
   No smoking while draining the gas tank! Use a safe container to store the gas.

6. Plug the gas line to fuel pump to prevent drain back from the pump. If the drain plug was removed, replace and tighten.
7. Disconnect all remaining small diameter fuel and evaporating system hoses.
8. Loosen clamps and remove the fuel filler hose.

   NOTE: On some earlier models, it may help to loosen the fuel tank mounting bolts before trying to disconnect the small hoses.

9. Remove mounting bolts evenly (one from each side) while supporting the tank.
10. Remove the gas tank.
11. During installation, be sure to connect the filler hose after the tank has been mounted, to prevent leakage at the connection.