Fuel tank removal (4JJ3 without DPD)

1. Component views

Fuel tank (Without protector)

Part name

  1. Fuel feed tube
  2. Fuel tank
  3. Fuel filler hose
  4. Breather hose
  5. Bolt
  6. Fuel tank band
  7. Fuel return tube
  8. Fuel return pipe
  9. Fuel feed pipe

Tightening torque

5: 68 N・m { 6.9 kgf・m / 50 lb・ft }

Fuel tank (With protector)

Part name

  1. Fuel feed tube
  2. Fuel tank
  3. Rubber pad
  4. Fuel filler hose
  5. Breather hose
  6. Bolt
  7. Fuel tank band
  8. Fuel return tube
  9. Protector
  10. Fuel return pipe
  11. Fuel feed pipe

Tightening torque

6: 68 N・m { 6.9 kgf・m / 50 lb・ft }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

3. Rear mudguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors rear mudguard removal".

4. Fuel filler hose disconnect

1) Place marks on the filler neck clamp, each fixing section, and band clip.

2) Remove the band clip from the rear axle breather hose. (2WD (High ride suspension specifications) and 4WD)

Legend

  1. Rear axle breather hose
  2. Fuel filler hose
  3. Band clip (2WD (High ride suspension specifications) and 4WD)

3) Disconnect the fuel filler hose from the fuel filler neck.

Caution

  • Seal the hose and pipe to prevent foreign material from entering.

4) Disconnect the breather hose from the fuel filler neck.

Caution

  • Seal the hose and pipe to prevent foreign material from entering.

Legend

  1. Breather hose
  2. Fuel filler hose
  3. Rear axle breather hose (2WD (High ride suspension specifications) and 4WD)

5. Fuel tube disconnect

1) Clean off any dirt adhered to the quick connector fitting of the fuel tube using air.

2) Disconnect the fuel feed pipe from the fuel feed tube.

Note

  • Hold the fuel tube with one hand while pushing the release button of the quick connector and pull out the quick connector with the other hand.

Caution

  • Do not use any tool.
  • Remove the fuel pipe (nylon tube) without twisting or damaging it.
  • Remove the fuel pipe and plug it so that fuel does not leak.
  • Cover the removed connector with a plastic bag to prevent foreign material or water from entering.

Legend

  1. Fuel feed pipe
  2. Fuel feed tube
  3. Release button

3) Disconnect the fuel return pipe from the fuel return tube.

Note

  • Hold the fuel tube with one hand while pushing the release button of the quick connector and pull out the quick connector with the other hand.

Caution

  • Do not use any tool.
  • Remove the fuel pipe (nylon tube) without twisting or damaging it.
  • Remove the fuel pipe and plug it so that fuel does not leak.
  • Cover the removed connector with a plastic bag to prevent foreign material or water from entering.

Legend

  1. Fuel return pipe
  2. Release button
  3. Fuel return tube

6. Fuel tank removal

1) Support the lower section of the fuel tank using the lifter.

2) Remove the fuel tank band from the frame.

Caution

  • Check that the cushion rubber is not torn.

3) Disconnect the connector from the fuel tank unit.

4) Lower the lifter and remove the fuel tank from the vehicle.

Caution

  • Do not let the fuel hose and fuel tube interfere with other components.
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