Removal And Installation

FUEL TANK

2WD : Removal and Installation

WARNING:
Be sure to read "General Precautions" when working on the fuel system. General Precautions.

REMOVAL
- Drain fuel from fuel tank if necessary. Removal And Installation.
- Perform work on level place.
1. Perform steps 2 to 7 of "REMOVAL" in "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP
ASSEMBLY" on fuel level sensor unit, fuel filter and fuel pump assembly. Removal And Installation.
2. Remove center muffler. Exploded View.
3. Remove insulator on vehicle side located above center and main mufflers.

4. Move parking brake cable (1) from the lower face of fuel tank.
Then remove clips for parking brake cable.

5. Disconnect fuel filler hose (4) at fuel tank side.

6. Disconnect EVAP hose and vent tube at the position shown in the figure.
- Instruction for quick connector of EVAP hose and vent tube, refer to the following:
EVAP hose

CAUTION:

- Quick connector (1) can be disconnected when the tabs
(F) are depressed completely. Never twist it more than necessary.

- Never use any tools to disconnected quick connector.
- Keep resin tube (C) away from heat. Be especially careful when welding near the resin tube.
- Prevent acid liquid such as battery electrolyte, etc. from getting on resin tube.
- Never bend or twist resin tube during installation and disconnection.
- Never remove the remaining retainer (2) on hard tube (or the equivalent) (A) except when resin tube or retainer is replaced.
- When resin tube or hard tube (or the equivalent) is replaced, also replace retainer with new one.

- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags (A) or something similar.
- Never insert plug, preventing damage on O-ring in quick connector.
Vent tube
- Remove quick connector in the following procedures.

- Pinch quick connector square-part (A) with your fingers, and pull out the quick connector (1) by hand.
- If quick connector and tube on vehicle are stuck, push and pull several times until they move, and pull out.

CAUTION:
- The tube can be removed when the tabs are completely depressed. Never twist it more than necessary.
- Never use any tools to disconnect quick connector.
- Keep the resin tube away from heat. Be especially careful when welding near the tube.
- Prevent acid liquid such as battery electrolyte, etc. from getting on the resin tube.
- Never bend or twist resin tube during installation and disconnection.

7. Support the center part of fuel tank (1) with transmission jack
(A).

CAUTION:
Securely support the fuel tank with a piece of wood (B).

8. Remove canister filter (1).

9. Remove fuel tank mounting bands (RH and LH).
10. Lower transmission jack carefully to remove fuel tank while holding it by hand.

CAUTION:
Fuel tank may be in an unstable condition because of the shape of fuel tank bottom. Never rely on jack too much. Be sure to hold tank securely.

INSTALLATION
Note the following, and install in the reverse order of removal.

Fuel Tank

1. Temporarily tighten bolts [except (4)] in numerical order as shown in the figure.

2. Tighten bolt (4) to specified torque, pressing fuel tank in the direction ( Backward Black Arrow) shown in the figure.
3. Tighten bolts [except (4)] to specified torque in the reverse order as shown in the figure.

Fuel Filler Hose
- Surely clamp fuel hose insert fuel filler hose to the length below.

- Be sure hose clamp is not placed on swelled area of fuel filler tube.

- Tighten the clamp band with the top mark (A) until the mark is on the bolt head flange.

EVAP Hose and Vent Tube
1. Check connections for damage or foreign material.
2. Align the matching side connection part with the center of shaft, and insert connector straight until it clicks.

3. After connecting, pull out quick connector and centralized under floor piping by hand. Check connections are secure.