REMOVAL AND INSTALLATION <4B1-4WD, 6B3>


Pre-removal operation
  • Fuel Pump Connector Disconnection [Refer to GROUP 13D - On-vehicle Service, Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ]. <4B1>
    Fuel Pump Connector Disconnection [Refer to GROUP 13C - On-vehicle Service, Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ]. <6B3>
  • Fuel Draining.
  • Propeller Shaft Removal (Refer to GROUP 25 - Propeller Shaft ).
  • Centre Exhaust Pipe Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler <4B1> ).
  • Centre Exhaust Pipe Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler <6B3> ).

 Post-installation operation
  • Centre Exhaust Pipe Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler <4B1> ).
  • Centre Exhaust Pipe Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler <6B3> ).
  • Propeller Shaft Installation (Refer to GROUP 25 - Propeller Shaft ).
  • Fuel Refilling.
  • Fuel Leak Check (Refer to ).




Removal steps


·
 Second seat assembly (Refer to GROUP 52A - Second Seat Assembly ).
<<A>>
1.
 Fuel tank pump and gauge assembly connector
<<A>>
2.
 Spare connector
<<A>>
 >>C<<
 3.
 Fuel main pipe connection
<<B>>
4.
 Fuel tank gauge unit connector


5.
 Fuel vapour pipe connection


6.
 Fuel filler hose


7.
 Fuel shut-off valve


8.
 Fuel filler neck breather hose


9.
 Parking brake rear cable clamp connection


·
 Rear suspension crossmember stay (Refer to GROUP 34 - Rear Suspension Crossmember ).
<<C>>
·
 Differential mount bracket mounting bolt
<<C>>
10.
 Fuel tank band
<<C>>
11.
 Fuel tank assembly


12.
 Fuel tank cap


13.
 Fuel filler neck assembly


14.
 Fuel vapour hose




Removal steps
<<D>>
 >>B<<
 15.
 Fuel tank gauge unit


16.
 Fuel tank gauge unit gasket


17.
 Fuel tank bracket and connector housing assembly


18.
 Fuel pump bracket plate
<<E>>
 >>A<<
 19.
 Suction hose connection
<<E>>
 >>A<<
 20.
 Fuel tank pump and gauge assembly


21.
 Fuel tank pump and gauge assembly gasket


22.
 Clip


23.
 Fuel tank lower protector


24.
 Fuel tank

REMOVAL SERVICE POINTS

<<A>> FUEL TANK PUMP AND GAUGE ASSEMBLY CONNECTOR/SPARE CONNECTOR/FUEL MAIN PIPE DISCONNECTION

1.Remove the floor inspection lid (LH).

2.Disconnect the fuel tank pump and gauge assembly connector and spare connector.

3.Insert a flat-tipped screwdriver (6 mm wide and 1 mm thick) into the retainer of the fuel main pipe connector.

4.
caution When pushing up the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.
Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel main pipe connector.
5.Disconnect the fuel main pipe from the fuel tank pump and gauge assembly.

<<B>> FUEL TANK GAUGE UNIT CONNECTOR DISCONNECTION

1.Remove the floor inspection lid (RH).

2.Disconnect the fuel tank gauge unit connector.

<<C>> DIFFERENTIAL MOUNT BRACKET MOUNTING BOLT/FUEL TANK BAND/FUEL TANK ASSEMBLY REMOVAL

1.Remove the mounting bolts of differential mount bracket and tilt the differential carrier assembly (Refer to GROUP 27B - Differential Carrier Assembly ).

2.Hold the fuel tank assembly with the transmission jack, and remove the connecting bolts of fuel tank band and the connecting nuts of fuel tank assembly.
3.Remove the fuel tank assembly in the tilt direction, paying attention not to bump it against the differential carrier assembly.

<<D>> FUEL TANK GAUGE UNIT REMOVAL
caution Pay attention not to damage the gauge unit and the float of fuel tank gauge unit when removing it from the fuel tank.

<<E>> SUCTION HOSE/FUEL TANK PUMP AND GAUGE ASSEMBLY REMOVAL
caution Pay attention not to damage the gauge unit and the float of fuel tank pump and gauge assembly when removing it from the fuel tank.

While removing the fuel tank pump and gauge assembly from the fuel tank, disconnect the suction hose from the fuel tank pump and gauge assembly to remove the fuel tank pump and gauge assembly from the fuel tank.

INSTALLATION SERVICE POINTS

>>A<< FUEL TANK PUMP AND GAUGE ASSEMBLY/SUCTION HOSE INSTALLATION
caution
  • Pay attention not to damage the gauge unit and the float of fuel tank pump and gauge assembly when installing it to the fuel tank.
  • Pay attention to prevent the float of fuel tank pump and gauge assembly from being trapped by the suction hose inside the fuel tank.
  • When installing the fuel tank pump and gauge assembly to the fuel tank, check that the gauge moving area moves smoothly.

While inserting the fuel tank pump and gauge assembly into the fuel tank, connect the suction hose to the fuel tank pump and gauge assembly to install the fuel tank pump and gauge assembly to the fuel tank.

>>B<< FUEL TANK GAUGE UNIT INSTALLATION
caution Pay attention not to damage the gauge unit and the float of fuel tank gauge unit when installing it to the fuel tank.

>>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 main pipe, slightly pull the fuel main pipe to check that it is connected securely. At this time, also check that there is approximately 1 mm play.
Install the fuel main pipe to the fuel tank pump and gauge assembly securely and push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel tank pump and gauge assembly.