REMOVAL AND INSTALLATION <4N1>



Pre-removal operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13D - 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> ].
  • Second seat assembly Removal (Refer to GROUP 52A - Second seat assembly ).

Post-installation operation
  • Second seat assembly Installation (Refer to GROUP 52A - Second 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 pump and gauge assembly connector
<<A>>
>>C<<
2.
Fuel main pipe connection
<<A>>
>>C<<
3.
Fuel return pipe connection


4.
Front floor under cover

>>B<<
5.
Fuel filler hose


6.
Fuel shut-off valve


7.
Fuel filler neck breather hose


8.
Fuel tank vapour hose


9.
Vapour cap


10.
Parking brake rear cable clamp connection
<<B>>

·
Differential mount bracket mounting bolt (Refer to GROUP 27B - Differential Carrier Assembly ).


11.
Fuel tank band


12.
Fuel tank assembly


13.
Fuel tank cap
<<C>>
>>A<<
14.
Rivet


15.
Filler neck protector


16.
Fuel filler neck assembly

REMOVAL SERVICE POINTS



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



1.Remove the floor inspection lid (LH).

2.Disconnect the fuel 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 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.

<<C>> RIVET REMOVAL


caution Be careful not to damage the fuel filler neck protector with the drill.

Use a drill (6.0 mm) to make a hole in the rivet to break it, and then remove the rivet.

INSTALLATION SERVICE POINTS



>>A<< RIVET INSTALLATION



Use a rivet tool shown in the illustration to connect the parts with rivets by the following procedures.
1.Insert the rivet into a corresponding location.
2.Set the rivet tool at a portion A of rivet.
3.While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4.Thin part of portion A of the rivet will be cut off and the part is fixed in position.

>>B<< 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.

>>C<< 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 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 pump and gauge assembly.