For 1990-2009 cars

## Fuel Tank Replacement LWB SWB

### Removal Procedure

#### Tools Required

EN-48536 Frame Support Tool (Engine Lower 65 mm Kit)

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
4. Remove the exhaust system. Refer to Exhaust System Replacement .
5. Remove the propeller shaft. Refer to Propeller Shaft Replacement .
6. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation .
7. Disconnect the evaporative emission (EVAP) line (1), by squeezing both sides of the line (as indicated in the illustration) and pulling it toward the rear of the vehicle.
8. Release the worm drive hose clamp (1) and remove the filler tube (2).
9. Disconnect the fuel feed line (1) and evaporative emission (EVAP) line (2). Refer to Plastic Collar Quick Connect Fitting Service .
10. Disconnect the fuel tank electrical connector (1).
11. Support the rear frame assembly using a suitable tool.
12. Remove the rear frame to chassis retaining bolts (1) and (2) and discard.
13. Support the rear frame using the bolt (1) from the EN-48536 special tool kit . Repeat for the opposite side.

Important: When lowering the rear frame use care not to over extend the rear brake hoses.

14. Support the rear frame using the bolt (1) from the EN-48536 special tool kit . Repeat for the opposite side.
15. Lower the rear frame approximately 50 millimetre's (2 in) (A) at the rear mounting surface between the rear frame and the chassis.
16. This will allow clearance to access the fuel tank strap bolts.
17. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement .
18. Disconnect the park brake rear cables from the park brake front cable equalizer bracket assembly. Refer to Parking Brake Front Cable Replacement .
19. Disconnect the evapouritive emission line (2) from the evapourative emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service .
20. Remove the fuel tank strap to chassis retaining bolts (1).
21. Position the fuel tank straps away from the fuel tank.
22. Carefully bend the fuel tank straps enough to allow the fuel tank to be removed.

Important: Make sure the following are free from the surrounding components while lowering the fuel tank:

• | The fuel tank wiring harness.

• | The fuel hoses at the chassis pipes.

23. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
24. Remove the following components if replacing just the fuel tank.

• | The primary fuel tank module - Refer to Primary Fuel Tank Module Replacement .

• | The secondary fuel tank module - Refer to Secondary Fuel Tank Module Replacement .

### Installation Procedure

1. Install the following components if fuel tank replacement was necessary.

• | The primary fuel tank module--Refer to Primary Fuel Tank Module Replacement .

• | The secondary fuel tank module--Refer to Secondary Fuel Tank Module Replacement .

Important: Make sure the following are properly routed while raising the fuel tank:

• | The fuel tank wiring harness.

• | The fuel hoses at the chassis pipes.

2. With the aid of an assistant, carefully raise the fuel tank to the vehicle.

Important: Make sure the fuel tank straps are not pressed into the fuel tank.

3. Carefully install the fuel tank straps back to their original form.
4. Position the fuel tank straps around the rear frame and upward into position, aligning the holes in the straps with the threaded holes in the chassis.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the fuel tank strap bolts.

Tighten
Tighten the fuel tank strap bolts to 20 N·m (15 lb ft).

6. Connect the evapourative emission line (2) to the evapourative emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service .
7. Raise the rear frame assembly using suitable tool.
8. Remove the special tool EN-48536 bolt (1) from the rear frame. Repeat for the opposite side.
9. Remove the special tool EN-48536 bolt (1) from the rear frame. Repeat for the opposite side.
10. Using a suitable tool clean the threaded holes in the rear chassis.

Important: Rear frame retaining bolts must not to be fully tightened at this stage.

11. Install the NEW rear frame to chassis retaining bolts (2).

Do not fully tighten at this stage.

12. After retaining bolts (1 and 2) are installed tighten to.

Tighten

• | First Pass: Tighten the bolts to 65 N·m (48 lb ft)

• | Final Pass: Tighten the bolts a further 125 degrees.

13. Remove the support tool.
14. Connect the fuel tank electrical connector (1).
15. Refer to Plastic Collar Quick Connect Fitting Service , in order to connect the following to the chassis bundle:

• | The fuel feed line

• | The fuel EVAP hose

16. Install the evaporative emission (EVAP) line (1), listen for an audible click to confirm fitting.
17. Connect the filler hose (2) to the fuel tank.

Tighten
Tighten the fuel filler tube hose clamp (1) to 4 N·m (35 lb in).

18. Connect the park brake rear cables to the park brake front cable equalizer bracket assembly. Refer to Parking Brake Front Cable Replacement .
19. Install the propeller shaft. Refer to Propeller Shaft Replacement .
20. Install the exhaust system. Refer to Exhaust System Replacement .
21. Install the right rear wheel. Refer to Tire and Wheel Removal and Installation .
22. Refill the fuel tank.
23. Inspect for fuel leaks.