REMOVAL AND INSTALLATION <4WD>


Pre-removal operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13B - On-vehicle Service, Reduce Pressurized Fuel Lines ).
  • Draining Fuel
  • Propeller Shaft Removal (Refer to GROUP 25 - Propeller Shaft ).
  • Exhaust Centre Pipe Removal (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).
  • 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 ).
  • Propeller Shaft Installation (Refer to GROUP 25 - Propeller Shaft ).
  • 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
<<B>>
4.
 Fuel tank gauge unit connector


5.
 Parking brake rear cable clamp connection


6.
 Fuel filler neck breather hose (Fuel filler neck side) connection

>>A<<
 7.
 Fuel filler hose (Fuel filler neck side) connection


·
 Rear suspension crossmember stay (Refer to GROUP 34 - Rear Suspension Crossmember ).


·
 Electronic control coupling harness cover (Refer to GROUP 27C - Electronic control 4WD )
<<C>>
·
 Electronic control coupling harness connector and harness clamp connection
<<C>>
·
 Differential mount bracket mounting bolt
<<C>>
8.
 Fuel tank band
<<C>>
9.
 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 GAUGE UNIT CONNECTOR DISCONNECTION

1.Remove the floor inspection lid (RH).

2.Disconnect the fuel tank gauge unit connector.

<<C>> ELECTRONIC CONTROL COUPLING HARNESS CONNECTOR AND HARNESS CLAMP/DIFFERENTIAL MOUNT BRACKET MOUNTING BOLT/FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL

1.Disconnect the electronic control coupling connector, the wiring harness clamp and the breather hose at the rear differential carrier (Refer to GROUP 27C - Electronic Control Coupling ).
2.Remove the differential mount bracket bolts, and tilt the differential carrier to hold it on a support stand (Refer to GROUP 27B - Rear axle ).

3.Support the fuel tank assembly on a transmission jack, and then remove the fuel tank band securing bolts and the fuel tank assembly connecting nuts.
4.Remove the fuel tank assembly while holding its tilted position and taking care not to strike it with the differential carrier.

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.