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Warning

• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing.

• A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching the vehicle body.

Caution

• Disconnecting/connecting the quick release connector without cleaning it may cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of foreign material.

1.Level the vehicle.

2.Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [L3 Turbo].)

3.Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [L3 Turbo].)

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4.Connect a long hose to the disconnected quick release connector and drain the fuel into a container used for collecting gasoline.

5.Drain the fuel from the fuel tank using the following procedure:

Using M-MDS

1. Connect the M-MDS to the DLC-2.

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2. Using the simulation function “FP”, start the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [L3 Turbo].)

Without using M-MDS

1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

2. Remove the fuel pump relay.

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Caution

• Short the specified terminals because shorting the wrong terminal of the main fuse block may cause malfunctions.

3. Using a jumper wire, short fuel pump relay terminals C and D in the main fuse block.

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4. Connect the negative battery cable and operate the fuel pump. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

Caution

• The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.

6.Stop the fuel pump using the following procedure.

Using M-MDS

1. Using the simulation function “FP”, stop the fuel pump. (See ON-BOARD DIAGNOSTIC TEST [L3 Turbo].)

2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

Without using M-MDS

1. Disconnect the negative battery cable to stop the fuel pump. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

7.Remove the rear seat cushion. (See REAR SEAT REMOVAL/INSTALLATION.)

8.Remove the service hole cover.

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9.Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [L3 Turbo].)

10.Remove the fuel gauge sender unit. (See FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION [L5, L3 Turbo].)

11.Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

12.Remove the propeller shaft (4WD). (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

13.Remove the rear under cover.

14.Remove the rear parking brake cable installation bolts, then move the rear parking brake cable out of the way.

15.Disconnect the joint hose from the fuel-filler pipe side.

16.Disconnect the breather hose from the fuel-filler pipe side.

17.Disconnect the quick release connector. (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [L3 Turbo].)

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18.Remove in the order indicated in the table

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Fuel Tank Insulator Removal Note

Caution

• Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may cause fuel leakage.

Note

• The fuel tank insulator is installed using rivets.

• When resin stalling the rivet, install the same rivet or M5 bolt and nut.

1.Push out the mandrel using a hammer and punch (2—2.8 mm {0.08—0.11 in} diameter).

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2.Remove the flange using a drill (5 mm {0.20 in} drill bit).

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Fuel-filler Pipe Removal Note

1.Remove the rear tire (LH). (See PRECAUTION.)

2.Remove the mudguard (LH).

3.Remove the air filter. (See AIR FILTER REMOVAL/INSTALLATION [L3 Turbo].)

4.Remove the fuel-filler pipe.

Evaporative Hose Installation Note (With check valve)

1.Install the protector and pad as shown in the figure.

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2.Secure the evaporative hose using a joint hose and band as shown in the figure.

(1)Insert the band on the right side of the vehicle through the front of the evaporative hose as A shown in the figure.

(2)Insert the band on the left side of the vehicle through the rear of the evaporative hose as B shown in the figure.

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Breather Hose Installation Note

1.Install the breather hose and clamp as shown in the figure.

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Joint Hose Installation Note

1.Install the joint hose and clamp as shown in the figure.

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