For 1990-2009 cars

#### Special Tools

SA9805E /KM-796-A Fuel Line Separator

### Removal Procedure

Note:

• | The fuel tank must be drained with a suitable, commercially-available fuel removal unit and suction hose - follow safety regulations and national legislation. The fuel tank is fitted with a refill limit float valve. This is located on the filler neck in the fuel tank. To prevent damaging the refill limit float valve, a suitable suction hose must be used.

• | In the presence of fuel vapors or escaping fuel - observe safety regulations and national legislation. Store drained fuel in a suitable, sealable container.

1. Open the hood.

Warning: Refer to Battery Disconnect Warning in the Preface section.

2. Disconnect the battery.
3. Disconnect the ground clamp from negative terminal.

Remove the nut

4. Remove the right rear wheel.
5. Raise the vehicle halfway.
6. Remove the right rear wheel housing inner paneling.

Remove the 2 nuts (1) and 2 bolts (2).

7. Disconnect the wiring harness of pressure sensor (atmospheric pressure) (1).

• | Disconnect the wiring harness plug (2).

• | Disconnect 3 cable ties (3).

8. Raise the vehicle halfway.
9. Disconnect the wiring harness of pressure sensor (atmospheric pressure) (1) from the fuel filler tube (2).
10. Disconnect 3 cable ties (3).
11. Remove the complete exhaust system. Refer to Exhaust System Replacement.
12. Disconnect the wiring harness plug of fuel tank fuel pump module (1).
13. Disconnect the vent hose (3) from vent pipe (1).
14. Disconnect the quick-release fitting (2) using SA9805E /KM-796-A.
15. Disconnect the fuel filler tube from the fuel tank.

Release the clamp (1).

16. Disconnect the rear fuel lines (3, 5) from the middle fuel lines (1, 2).
17. Disconnect the 2 quick-release fittings.

Press release (4).

18. Remove the parking brake cable from bracket (1) in 7 places.
19. Retract the jack.
20. Remove the 2 fuel tank holding straps.

Remove the 4 bolts (1).

Note: Wiring harness must be passed over rear axle.

21. With the aid of an assistant, remove fuel tank.
22. Remove the evaporative emission canister (1).

• | Remove the vent line from fuel tank to evaporative emission canister (2).

• | Disconnect the quick-release fitting.

• | Remove the vent line from evaporative emission canister to rear purge valve (4).

• | Disconnect the quick-release fitting.

• | Disconnect the rear vent line (3).

• | Disconnect the quick-release fitting.

• | Release the bracket and remove the evaporative emission canister.

23. Remove the rear vent line from the bracket.

### Installation Procedure

1. Install the rear vent line at bracket.
2. Install the evaporative emission canister.

• | Install the evaporative emission canister at bracket.

• | Install the rear vent line.

• | Connect the quick-release fitting.

• | Connect the vent line at evaporative emission canister to rear purge valve.

• | Connect the quick-release fitting.

• | Connect the vent line at fuel tank to evaporative emission canister.

• | Connect the quick-release fitting.

3. With the aid of an assistant, position the fuel tank to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

4. Connect the 2 fuel tank holding straps.

Tighten
Tighten the 4 fuel tank holding strap bolts to 23 N·m (17 lb ft).

5. Extend the jack.
6. Install the parking brake cable to bracket in 7 places.
7. Install the rear fuel lines to middle fuel lines.

Connect the 2 quick-release fittings.

8. Install the fuel filler tube to fuel tank.

Tighten
Tighten the clamp to 3.5 N·m (31 lb in).

9. Connect the vent hose to vent pipe.

Connect the quick-release fitting.

10. Connect the wiring harness plug of fuel tank fuel pump module.
11. Install the complete exhaust system. Refer to Exhaust System Replacement.
12. Connect the wiring harness of pressure sensor (atmospheric pressure).

Connect the 3 cable ties.

13. Lower the vehicle halfway.
14. Connect the wiring harness of pressure sensor (atmospheric pressure).

• | Connect the wiring harness plug.

• | Connect the 3 cable ties.

15. Install the right rear wheel housing inner paneling.

Install the 2 nuts and 2 bolts.

Tighten

• | Tighten the 2 rear wheel housing inner paneling nuts to 2.5 N·m (22 lb in).

• | Tighten the 2 rear wheel housing inner paneling bolts to 2.5 N·m (22 lb in).

16. Mount the right rear wheel.
17. Lower the vehicle halfway.

Tighten
Tighten the right rear wheel bolts to 110 N·m (81 lb ft).

18. Connect the battery.
19. Connect the ground clamp to negative terminal.

Tighten
Tighten the ground clamp nut to 5 N·m (44 lb in).

20. For programming procedures, refer to Control Module References.
21. Close the hood.