REMOVAL AND INSTALLATION <2WD>


Pre-removal operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13B - On-vehicle Service, Reduce Pressurized Fuel Lines ).
  • Draining Fuel
  • Exhaust Centre Pipe Removal [Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter <4N1>].
  • Rear Seat Cushion Assembly Removal (Refer to GROUP 52A - Rear Seat Assembly ).

 Post-installation operation
  • Rear Seat Cushion Assembly Installation (Refer to GROUP 52A - Rear Seat Assembly ).
  • Exhaust Centre Pipe Removal [Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter <4N1>].
  • Refilling Fuel
  • Checking for Fuel Leaks (Refer to ).




Removal steps
<<A>>
1.
 Fuel tank pump and gauge assembly connector
<<A>>
 >>B<<
 2.
 Fuel main pipe connection
<<A>>
 >>B<<
 3.
 Fuel return pipe connection


4.
 Parking brake rear cable clamp connection


5.
 Fuel filler neck breather hose (Fuel filler neck side) connection

>>A<<
 6.
 Fuel filler hose (fuel filler neck side) connection
<<B>>
7.
 Fuel tank band
<<B>>
8.
 Fuel tank assembly

REMOVAL SERVICE POINTS

<<A>> FUEL TANK PUMP AND GAUGE ASSEMBLY CONNECTOR/FUEL MAIN PIPE/FUEL RETURN PIPE DISCONNECTION

1.Remove the floor inspection lid (LH).

2.Disconnect the fuel tank pump and gauge assembly connector.

3.Insert a flat-tip screwdriver (6 mm wide and 1 mm thick) into the retainer of the fuel main pipe connector and fuel return pipe connector.

4.
caution When pushing up the retainer of the fuel main pipe connector and fuel return pipe connector, pay attention to avoid damage to the retainer.
Turn the flat-tip screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel main pipe connector and fuel return pipe connector.
5.Disconnect the fuel main pipe and fuel return pipe from the fuel tank pump and gauge assembly.

<<B>> FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL

1.Hold the fuel tank assembly with the transmission jack, and remove the connecting bolts of fuel tank band and the connecting nuts of fuel tank assembly.
2.Remove the fuel tank assembly.

INSTALLATION SERVICE POINTS

>>A<< FUEL FILLER HOSE CONNECTION

After connecting the fuel filler hose, tighten the bolts of hose clamp so that the tightening dimension is 4.5 ± 1.5 mm.

>>B<< FUEL RETURN PIPE/FUEL MAIN PIPE CONNECTION

1.Pull up the retainer of fuel main pipe and fuel return pipe to unlock before installing.

2.
caution
  • When pushing in the retainer of the fuel main pipe connector and fuel return pipe connector, pay attention to avoid damage to the retainer.
  • After the installation of the fuel main pipe connector and fuel return pipe connector, slightly pull the fuel main pipe and fuel return pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm play.
Install the fuel main pipe and fuel return pipe to the fuel tank pump and gauge assembly securely and push in the retainer of the fuel main pipe connector and fuel return pipe connector to lock the fuel main pipe and fuel return pipe and fuel tank pump and gauge assembly.