Fuel Tank: Service and Repair
REMOVAL1. DISCHARGE FUEL SYSTEM PRESSURE
a. Discharge the fuel system pressure
2. REMOVE DECK BOARD SUB-ASSEMBLY
3. REMOVE REAR SEAT TRACK BRACKET COVER OUTER
4. REMOVE REAR SEAT ASSEMBLY RH
5. REMOVE REAR SEAT ASSEMBLY LH
6. REMOVE REAR DOOR SCUFF PLATE LH
7. REMOVE REAR FLOOR SERVICE HOLE COVER
8. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAGE
9. DRAIN FUEL
10. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY (4WD TYPE)
11. REMOVE EXHAUST PIPE ASSEMBLY CENTER
12. REMOVE FRONT FLOOR HEAT INSULATOR NO.3
13. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.4 (4WD TYPE)
a. Remove the 2 bolts and support bracket.
14. REMOVE FUEL TUBE PROTECTOR NO.1
a. Remove the 2 clips and unfasten the claw, and remove the tube protector.
15. REMOVE FUEL TANK PROTECTOR NO.1
a. Remove the 4 nuts and fuel tank protector.
16. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY. NO.1
a. Remove the 3 clips [A], 6 nuts and tank protector.
17. 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 shown in the illustration [A].
2. Pull out the fuel pump tube [B].
NOTE:
- Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
- Be careful of mud. The connector's Oring, which seals the pipe and connector, becomes contaminated easily.
- 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 it. Then pull out the connector from the pipe.
b. Disconnect the fuel tank vent hose hose.
1. Push the connector deep into the charcoal canister to release the locking tab [A].
2. Pinch portion "A".
3. Pull out the connector [B].
c. Disconnect the fuel tank breather tube No.3.
1. Lower the connector checker slightly [A].
2. Pinch the tube connector [B].
3. Pull out the breather tube [C].
NOTE:
- Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
- Be careful of mud. The connector's Oring, which seals the pipe and connector, becomes contaminated easily.
- 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 it. Then pull out the connector from the pipe.
d. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
e. Disconnect the fuel tank wire connector "A".
f. Remove the connector clamp "B".
g. Set up a transmission jack under the fuel tank.
h. Remove the 4 bolts "C" and 2 fuel tank bands.
i. Remove the 2 nuts "D".
j. Operate the transmission jack and remove the fuel tank.
18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY
a. Unfasten the 2 claws and remove the tube.
19. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Loosen the hose clamp bolt and remove the hose.
20. REMOVE FUEL TANK WIRE
a. Disconnect the vapor pressure sensor connector.
b. Unfasten the 4 claws and remove the wire
21. REMOVE VAPOR PRESSURE SENSOR ASSEMBLY
a. Remove the tube joint clip [A].
b. Pull out the vapor pressure sensor [B].
22. REMOVE FUEL TANK VENT HOSE
a. Push the connector deep into the charcoal canister to release the locking tab [A].
b. Pinch portion "A".
c. Pull out the connector [B].
d. Unfasten the claw and remove the vent hose [C].
23. REMOVE TANK SUCTION TUBE SUPPORT
a. Remove the tube support from the fuel tank.
24. REMOVE FUEL TANK SIDE PLATE
a. Remove the bolt and nut, and then remove the fuel tank side plate and the fuel tank bracket.
25. REMOVE FUEL TANK CUSHION SET
a. Remove the cushion set and cushion No. 5. Cushion Set 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 tube support as shown in the illustration.
4. INSTALL FUEL TANK VENT HOSE
5. INSTALL VAPOR PRESSURE SENSOR ASSEMBLY
a. Push and hold down the vapor pressure sensor [A].
b. Install the fuel tube joint clip to the sensor [B].
NOTE:
- Check that there are no scratches 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 trying to pull 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. Operate the transmission jack and 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 [A] 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 trying to pull them apart.
2. Return the connector [B] checker to its original position.
i. Connect the fuel tank vent hose.
j. Connect the fuel pump tube.
1. Push the quick connector [A] in the direction of the white arrow.
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 trying to pull them.
2. Push up on the retainer until the claws lock.
10. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1
a. Install the tank protector 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)
12. INSTALL FUEL TUBE PROTECTOR NO.1
13. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.4 (4WD TYPE)
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 SUCTION TUBE ASSEMBLY WITH PUMP AND GAGE
17. ADD FUEL
18. CHECK FUEL LEAKAGE
a. Check for the fuel leaks.
19. CHECK EXHAUST GAS LEAKAGE
20. INSTALL REAR FLOOR SERVICE HOLE COVER
21. INSTALL REAR DOOR SCUFF PLATE LH
22. INSTALL REAR SEAT ASSEMBLY LH
23. INSTALL REAR SEAT ASSEMBLY RH
24. INSTALL REAR SEAT TRACK BRACKET COVER OUTER
25. INSTALL DECK BOARD SUB-ASSEMBLY
26. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY (4WD TYPE)
27. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSEMBLY (4WD TYPE)
28. ADD TRANSFER OIL (4WD TYPE)
29. INSPECT TRANSFER OIL (4WD TYPE)