REMOVAL AND INSTALLATION <4B1-Except PHEV, 4J1>



Pre-removal operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13A - On-vehicle Service, Reduce Pressurized Fuel Lines ).
  • Fuel Draining.
  • Propeller Shaft Assembly Removal (Refer to GROUP 25 - Propeller Shaft ).
  • Exhaust Centre Pipe Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler ).

Post-installation operation
  • Exhaust Centre Pipe Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler ).
  • Propeller Shaft Assembly Installation (Refer to GROUP 25 - Propeller Shaft ).
  • Fuel Refilling.
  • Fuel Leak Check (Refer to ).





Removal steps


·
Second seat assembly (Refer to GROUP 52A - Second Seat Assembly ).
<<A>>

1.
Fuel pump and gauge assembly connector
<<A>>
>>C<<
2.
Fuel main pipe connection
<<B>>

3.
Fuel gauge unit connector


4.
Fuel vapour pipe connection


5.
Front floor under cover

>>B<<
6.
Fuel filler hose


7.
Fuel shut-off valve


8.
Fuel filler neck breather hose


9.
Parking brake rear cable clamp connection
<<C>>

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

10.
Fuel tank band
<<C>>

11.
Fuel tank assembly


12.
Fuel tank cap
<<D>>
>>A<<
13.
Rivet


14.
Filler neck protector


15.
Fuel filler neck assembly


16.
Fuel vapour hose

REMOVAL SERVICE POINTS



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



1.Remove the floor inspection lid (LH).

2.Disconnect the fuel pump and gauge assembly connector.

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

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

<<B>> FUEL GAUGE UNIT CONNECTOR DISCONNECTION



1.Remove the floor inspection lid (RH).

2.Disconnect the fuel gauge unit connector.

<<C>> DIFFERENTIAL MOUNT BRACKET MOUNTING BOLT/FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL



1.Remove the fuel tank, continuously checking that it does not make contact with the 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>> 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 MAIN PIPE CONNECTION



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

2.
caution
  • When pushing in the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.
  • After the installation of the fuel main pipe, slightly pull the fuel main 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 to the fuel pump and gauge assembly securely and push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump and gauge assembly.