REMOVAL AND INSTALLATION <BSY>



Pre-removal operation
  • Second seat assembly Removal (Refer to GROUP 52A - Second Seat Assembly ).
  • Fuel Draining.
  • Propeller Shaft Removal (Refer to GROUP 25 - Propeller Shaft ).
  • Centre Exhaust Pipe Removal (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter <BSY> ).

Post-installation operation
  • Centre Exhaust Pipe Installation (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter <BSY> ).
  • Propeller Shaft Installation (Refer to GROUP 25 - Propeller Shaft ).
  • Fuel Refilling.
  • Second seat assembly Installation (Refer to GROUP 52A - Second Seat Assembly ).
  • Fuel Leak Check (Refer to ).





Removal steps
<<A>>

1.
Fuel tank pump and gauge assembly connector
<<A>>

2.
Spare connector
<<A>>
>>C<<
3.
Fuel main pipe connection
<<A>>
>>C<<
4.
Fuel return pipe connection
<<B>>

5.
Fuel tank gauge unit connector


6.
Fuel filler hose


7.
Fuel shut-off valve


8.
Fuel filler neck breather hose


9.
Fuel vapour hose


10.
Vapour cap


11.
Parking brake rear cable clamp connection


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

·
Differential mount bracket mounting bolt
<<C>>

12.
Fuel tank band
<<C>>

13.
Fuel tank assembly


14.
Fuel tank cap


15.
Fuel filler neck assembly




Removal steps
<<D>>
>>B<<
16.
Fuel tank gauge unit


17.
Fuel tank gauge unit gasket


18.
Fuel tank bracket and connector housing assembly


19.
Fuel pump bracket plate
<<E>>
>>A<<
20.
Suction hose connection
<<E>>
>>A<<
21.
Fuel tank pump and gauge assembly


22.
Fuel tank pump and gauge assembly gasket


23.
Clip


24.
Fuel tank lower protector


25.
Fuel tank

REMOVAL SERVICE POINTS



<<A>> FUEL TANK PUMP AND GAUGE ASSEMBLY CONNECTOR/SPARE 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 and spare 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>> DIFFERENTIAL MOUNT BRACKET MOUNTING BOLT/FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL



1.Remove the mounting bolts of differential mount bracket and tilt the differential carrier assembly (Refer to GROUP 27B - Differential Carrier Assembly ).

2.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.
3.Remove the fuel tank assembly in the tilt direction, paying attention not to bump it against the differential carrier assembly.

<<D>> FUEL TANK GAUGE UNIT REMOVAL


caution Pay attention not to damage the gauge unit and the float of fuel tank gauge unit when removing it from the fuel tank.

<<E>> SUCTION HOSE/FUEL TANK PUMP AND GAUGE ASSEMBLY REMOVAL


caution Pay attention not to damage the gauge unit and the float of fuel tank pump and gauge assembly when removing it from the fuel tank.

While removing the fuel tank pump and gauge assembly from the fuel tank, disconnect the suction hose from the fuel tank pump and gauge assembly to remove the fuel tank pump and gauge assembly from the fuel tank.

INSTALLATION SERVICE POINTS



>>A<< FUEL TANK PUMP AND GAUGE ASSEMBLY/SUCTION HOSE INSTALLATION


caution
  • Pay attention not to damage the gauge unit and the float of fuel tank pump and gauge assembly when installing it to the fuel tank.
  • Pay attention to prevent the float of fuel tank pump and gauge assembly from being trapped by the suction hose inside the fuel tank.
  • When installing the fuel tank pump and gauge assembly to the fuel tank, check that the gauge moving area moves smoothly.

While inserting the fuel tank pump and gauge assembly into the fuel tank, connect the suction hose to the fuel tank pump and gauge assembly to install the fuel tank pump and gauge assembly to the fuel tank.

>>B<< FUEL TANK GAUGE UNIT INSTALLATION


caution Pay attention not to damage the gauge unit and the float of fuel tank gauge unit when installing it to the fuel tank.

>>C<< FUEL MAIN PIPE CONNECTION/FUEK RETURN 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.