Fuel Tank: Service and Repair

Fuel Tank:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE DECK BOARD SUB-ASSEMBLY
3. REMOVE REAR SEAT TRACK BRACKET COVER OUTER
4. REMOVE REAR SEAT TRACK BRACKET COVER OUTER
5. REMOVE REAR SEAT ASSEMBLY RH
6. REMOVE REAR SEAT ASSEMBLY LH
7. REMOVE REAR DOOR SCUFF PLATE LH
8. REMOVE DECK SIDE TRIM COVER LH
9. REMOVE REAR SEAT SIDE COVER LH
10. REMOVE REAR FLOOR SERVICE HOLE COVER
11. REMOVE SUCTION TUBE SUB-ASSEMBLY
12. DRAIN FUEL
13. REMOVE ENGINE UNDER COVER NO.2
14. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
15. REMOVE EXHAUST PIPE ASSEMBLY CENTER
16. REMOVE FRONT FLOOR HEAT INSULATOR NO.3

17. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.4

a. 4WD type
1. Remove the 2 bolts, and then remove the exhaust pipe support bracket No. 4.

18. REMOVE FUEL TUBE PROTECTOR NO.1

a. Remove the 2 clips and unfasten the claw, and then remove the fuel tube protector No. 4.

19. REMOVE FUEL TANK PROTECTOR NO.1

a. Remove the 4 nuts, and then remove the fuel tank protector No. 1.

20. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1

a. Remove the 3 clips (A) and 6 nuts, and then remove the fuel tank protector No. 1.

21. REMOVE FUEL TANK ASSEMBLY
a. Disconnect the fuel pump tube.

1. Pinch the projection of the retainer to remove the lock claws and pull down it as show in the illustration.
2. Pull out the fuel pump tube.

NOTE:
- Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
- Be careful of mud because the quick connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.

b. Disconnect the fuel tank vent hose.

1. Deeply push the connector to release the locking tab.
2. Pinch portion A.
3. Pull out the connector.

c. Disconnect the fuel tank breather tube No. 3.

1. Pinch the tube connector and then pull out the fuel tank breather tube No. 3.

NOTE:
- Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.

d. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
e. Disconnect the fuel tank wire connector.

f. Remove the connector clamp.
g. Set up a transmission jack under the fuel tank.

h. Remove the 4 bolts, and then remove the 2 fuel tank bands.
i. Remove the 2 nuts.
j. Operating the transmission jack and remove the fuel tank.

22. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY

a. Unfasten the 2 claws, and then remove the fuel pump tube.

23. REMOVE FUEL TANK TO FILLER PIPE HOSE

a. Loosen the hose clamp bolt, and then remove the fuel tank to filler pipe hose.

24. REMOVE FUEL TANK WIRE

a. Disconnect the vapor pressure sensor connector.
b. Unfasten the 4 claws, and then remove the fuel tank wire.

25. REMOVE VAPOR PRESSURE SENSOR ASSEMBLY

a. Remove the tube joint clip.
b. Pull out the vapor pressure sensor.

26. REMOVE FUEL TANK VENT HOSE

a. Deeply push the connector to release the locking tab.
b. Pinch portion A.
c. Pull out the connector.
d. Unfasten the claw, and then remove the fuel tank vent hose.

27. REMOVE TANK SUCTION TUBE SUPPORT

a. Remove the tank suction tube support from the fuel tank.

28. REMOVE FUEL TANK SIDE PLATE

a. Remove the bolt and nut, and then remove the fuel tank side plate and the fuel tank bracket.

29. REMOVE FUEL TANK CUSHION SET

a. Remove the fuel tank cushion set and fuel tank cushion No. 5.

INSTALLATION

1. INSTALL FUEL TANK CUSHION SET

2. INSTALL FUEL TANK SIDE PLATE

Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)

3. INSTALL TANK SUCTION TUBE SUPPORT
a. Install a new tank suction tube support as shown in the illustration.

4. INSTALL FUEL TANK VENT HOSE

5. INSTALL VAPOR PRESSURE SENSOR ASSEMBLY

a. Install the vapor pressure sensor with the fuel tube joint clip.

NOTE:
- Check that there is no scratch or foreign objects on the connecting parts.
- Check that the fuel tube joint is fully inserted.
- Check that the fuel tube joint clip is on the collar of the fuel tube joint.
- After installing the tube joint clip, check if the fuel joint is securely connected by pulling it.

6. INSTALL FUEL TANK WIRE

7. INSTALL FUEL TANK TO FILLER PIPE HOSE

8. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY

9. INSTALL FUEL TANK ASSEMBLY
a. Set up the fuel tank to the transmission jack.
b. Operating the transmission jack and the install the fuel tank.
c. Tighten the 2 nuts.

Torque: 20 N.m (200 kgf.cm, 14 ft.lbf)

d. Install the 2 fuel tank bands with the 4 bolts.

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

e. Install the connector clamp.
f. Connect the fuel tank wire connector.
g. Connect the fuel tank to filler pipe hose.
h. Connect the fuel tank breather tube No. 3.
1. Push the quick connector to the pipe until it makes "click" sound.

NOTE:
- Check if there is any damage or foreign objects on the connected part.
- After connecting, check if the quick connector and the pipe are securely connected by pulling on them.

10. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1
a. Install the fuel tank protector No. 1 with the 6 nuts.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

b. Install 3 new clips. 11. INSTALL FUEL TANK PROTECTOR NO.1

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

11. INSTALL FUEL TANK PROTECTOR NO.1

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

12. INSTALL FUEL TUBE PROTECTOR NO.1

13. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.4

Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)

14. INSTALL FRONT FLOOR HEAT INSULATOR NO.3
15. INSTALL EXHAUST PIPE ASSEMBLY CENTER
16. INSTALL FUEL
17. INSTALL SUCTION TUBE SUB-ASSEMBLY
18. CHECK FOR FUEL LEAKS
19. CHECK FOR EXHAUST GAS LEAKS
20. INSTALL REAR FLOOR SERVICE HOLE COVER
21. INSTALL REAR SEAT SIDE COVER LH
22. INSTALL DECK SIDE TRIM COVER LH
23. INSTALL REAR DOOR SCUFF PLATE LH
24. INSTALL REAR SEAT ASSEMBLY LH
25. INSTALL REAR SEAT ASSEMBLY RH
26. INSTALL REAR SEAT TRACK BRACKET COVER OUTER
27. INSTALL REAR SEAT TRACK BRACKET COVER OUTER
28. INSTALL DECK BOARD SUB-ASSEMBLY
29. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
30. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
31. ADD TRANSFER OIL
32. INSPECT TRANSFER OIL
33. INSTALL ENGINE UNDER COVER ASSEMBLY