Removal and Replacement

REMOVAL AND INSTALLATION [AWD]









[FUEL TANK]










[FUEL TANK FILLER TUBE]






REMOVAL SERVICE POINTS

[[A]] FUEL PUMP MODULE CONNECTOR/FUEL TANK DIFFERENTIAL PRESSURE SENSOR CONNECTOR/FUEL MAIN PIPE DISCONNECTION





1. Remove the floor inspection lid (LH).





2. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
3. Release the fuel pressure in the fuel line Service and Repair).





4. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04 inch) thick] into the retainer of the fuel main pipe.





5. Turn the flat-tip screwdriver about 90 degrees to push up the retainer, and disconnect the fuel main pipe from the fuel pump module.

[[B]] FUEL LEVEL SENSOR (SUB) CONNECTOR DISCONNECTION





1. Remove the floor inspection lid (RH).





2. Disconnect the fuel level sensor (sub) connector.

[[C]] ELECTRONIC CONTROL COUPLING HARNESS CONNECTOR AND HARNESS CLAMP/DIFFERENTIAL MOUNT BRACKET MOUNTING BOLT/FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL





1. Disconnect the electronic control coupling connector, the wiring harness clamp and the breather hose at the rear differential carrier Service and Repair).
2. Remove the differential mount bracket bolts, and tilt the differential carrier to hold it on a support stand Removal and Replacement).





3. Support the fuel tank assembly on a transmission jack, and then remove the fuel tank band securing bolts and the fuel tank assembly connecting nuts.
4. Remove the fuel tank assembly while holding its tilted position and taking care not to strike it with the differential carrier.

[[D]] RIVET REMOVAL

CAUTION:
Be careful not to score the heat protector by drill.





Use a 6.0 / diameter / mm drill 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 parts is fixed in position.

]]B[[ HOSE CLAMP INSTALLATION





Connect the fuel filler hose, and tighten the bolt of hose clamp so that the bolt tightening dimension of the hose clump becomes 4.5 ± 1.5 mm (0.18 ± 0.06 inch).

]]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 high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04 inch) play.

Install the fuel main pipe to the fuel pump module securely and push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump module.