Fuel Tank Replacement

Except KZ model:


1.Drain the fuel tank: Remove the fuel pump assenbly. Using a hand pump, hose and container suitable for gasoline, draw the fuel from the fuel tank.

2.Jack up the vehicle, and support it with jackstands.

3.4WD model:
Remove the propeller shaft. Remove the rear differential mounting bolt (A), then support it with jackstands.

KG, KS, KE, KR models: 

Except KG, KS, KE, KR models: 

4.Loosen the Evaporative Emission (EVAP) canister bracket bolt.

5.Remove the fuel tank guard (B).

6.Loosen the clamp (C).

7.Disconnect the fuel vapor hose (D), hoses (E) and wire stay bolts (F). Slide back the clamps, then twist the hoses as you pull to avoid damaging them.

8.Except KG, KS, KE, KR models:
Remove the fuel filter bracket bolt (G).

9.Place a jack, or other support, under the fuel tank (H).

10.Remove the strap bolts, and the strap (I).

11.Remove the fuel tank.

12.Install the remaining parts in the reverse order of removal.

KZ model:


1.Relieve the fuel pressure.

2.Fold the rear seats forward, and pull back the carpet to expose the access panel.

3.Remove the access panel, disconnect the quick connect fittings from the fuel pump.

4.Jack up the vehicle, and support it with jackstands.

5.Remove the drain bolt (A), and drain the fuel into an approved container.

6.Remove the propeller shaft. Remove the rear differential mounting bolt (B), then support it with jackstands.

 

7.Loosen the Evaporative Emission (EVAP) canister bracket bolt.

8.Remove the fuel tank guard (C).

9.Loosen the clamp (D).

10.Disconnect the fuel vapor hose (E) and hoses (F) and wire stay bolts (G). Slide back the clamps, then twist the hoses as you pull to avoid damaging them.

11.Remove the fuel filter bracket (H).

12.Place a jack, or other support, under the fuel tank (I).

13.Remove the strap bolts, and the strap (J).

14.Remove the fuel tank.

15.Install the drain bolt with a new washer (K), then coat the drain bolt with Noxrust 124B or equivalent. Allow the Noxrust or equivalent to dry for 20 minutes.

16.Install the remaining parts in the reverse order of removal.