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 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 [A] and pull down it as shown in the illustration.
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 O-ring, 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.
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 O-ring, 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. Set up a transmission jack under the fuel tank.
f. Remove the 4 bolts [A] and 2 fuel tank bands.
g. Remove the 2 nuts [B].
h. 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 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.
21. REMOVE TANK SUCTION TUBE SUPPORT
a. Remove the tube support from the fuel tank.
22. REMOVE FUEL TANK SIDE PLATE
a. Remove the bolt and nut side plate and tank bracket.
23. REMOVE FUEL TANK CUSHION SET
a. Remove the cushion set and 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 FUEL TANK TO FILLER PIPE HOSE
6. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
7. INSTALL FUEL TANK ASSEMBLY
a. Set up the fuel tank to the transmission jack.
b. Operate the transmission jack and the 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 checker [B] 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 pulling on them.
2. Push up on the retainer [B] until the claws lock.
8. 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 "A".
9. INSTALL FUEL TANK PROTECTOR NO.1
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
10. INSTALL FUEL TUBE PROTECTOR NO.1
11. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.4 (for 4WD)
Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)
12. INSTALL FRONT FLOOR HEAT INSULATOR NO.3
13. INSTALL EXHAUST PIPE ASSEMBLY CENTER
14. ADD FUEL
15. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAGE
16. CHECK FUEL LEAKAGE
a. Check for fuel leaks
17. CHECK EXHAUST GAS LEAKAGE
18. INSTALL REAR FLOOR SERVICE HOLE COVER
19. INSTALL REAR DOOR SCUFF PLATE LH
20. INSTALL REAR SEAT ASSEMBLY LH
21. INSTALL REAR SEAT ASSEMBLY RH
22. INSTALL REAR SEAT TRACK BRACKET COVER OUTER
23. INSTALL DECK BOARD SUB-ASSEMBLY
24. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY (4WD TYPE)
25. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSEMBLY (4WD TYPE)
26. ADD TRANSFER OIL (4WD TYPE)
27. INSPECT TRANSFER OIL (4WD TYPE)