REMOVAL AND INSTALLATION <4M4>

<SHORT WHEELBASE>

Fuel tank removal steps 1. Fuel tank under protector 2. Fuel filler hose connection 3. Fuel main hose connection 4. Fuel return hose connection <<A>> >>B<< 5. Fuel tank band <<A>> >>B<< 6. Fuel filler neck breather hose connection <<A>> >>B<< 7. Fuel tank vapour hose connection <<A>> >>B<< 8. Fuel tank harness connector connection <<A>> >>B<< 9. Fuel tank assembly

Fuel tank removal steps 10. Fuel main hose 11. Fuel return hose 12. Fuel tank vapour hose 13. Fuel hose connector 14. Fuel tank hose 15. Valve assembly 16. Packing 17. Fuel tank main hose 18. Fuel tank return hose 19. Fuel suction hose connection 20. Fuel filter pipe assembly 21. Packing 22. Fuel tank harness <<B>> >>A<< 23. Fuel tank gauge unit 24. Packing 25. Fuel tank

Fuel filler neck removal steps 2. Fuel filler hose connection <<A>> >>B<< 6. Fuel filler neck breather hose connection <<A>> >>B<< 7. Fuel tank vapour hose connection 26. Fuel tank cap 27. Fuel filler neck protector 28. Fuel filler neck 29. Fuel filler neck gasket 30. Fuel filler hose 31. Fuel tank vapour hose 32. Fuel filler neck breather hose 33. Fuel filler neck pipe 34. Fuel filler neck breather hose 35. Fuel filler neck vapour hose 36. Fuel filler neck vapour hose 37. Fuel filler neck check valve

<LONG WHEELBASE>

Fuel tank removal steps 1. Fuel tank under protector 2. Fuel filler hose connection 3. Fuel main hose connection 4. Fuel return hose connection <<A>> >>B<< 5. Fuel tank band, front <<A>> >>B<< 6. Fuel tank band, rear <<A>> >>B<< 7. Fuel filler neck breather hose connection <<A>> >>B<< 8. Fuel tank vapour hose connection <<A>> >>B<< 9. Fuel tank harness connector connection <<A>> >>B<< 10. Fuel tank assembly

Fuel tank removal steps 11. Fuel main hose 12. Fuel return hose 13. Fuel tank vapour hose 14. Fuel hose connector 15. Fuel tank hose 16. Valve assembly 17. Packing 18. Fuel tank main hose 19. Fuel tank return hose 20. Fuel suction hose connection 21. Fuel filter pipe assembly 22. Packing 23. Fuel tank harness <<B>> >>A<< 24. Fuel tank gauge unit 25. Packing 26. Fuel tank

Fuel filler neck removal steps 2. Fuel filler hose connection <<A>> >>B<< 7. Fuel filler neck breather hose connection <<A>> >>B<< 8. Fuel tank vapour hose connection 27. Fuel tank cap 28. Fuel filler neck protector 29. Fuel filler neck 30. Fuel filler neck gasket 31. Fuel filler hose 32. Fuel tank vapour hose 33. Fuel filler neck breather hose 34. Fuel filler neck pipe 35. Fuel filler neck breather hose 36. Fuel filler neck vapour hose 37. Fuel filler neck vapour hose 38. Fuel filler neck check valve

1. caution When moving the stabilizer bar to the position where it will not interfere with the fuel tank assembly removal, be careful not to damage the ball joint section of the stabilizer link. Before removing the fuel tank assembly, remove the clamp of the stabilizer bar, and move the stabilizer bar to the position where it will not interfere with the fuel tank assembly removal. (Refer to GROUP 34 - Stabilizer Bar ).

2.Support the fuel tank assembly using the transmission jack, and remove the fuel tank band and fuel tank assembly mounting nuts. 3.Using the transmission jack while taking care of the fuel filler neck breather hose, fuel tank vapour hose and the fuel tank harness, lower the fuel tank assembly until the fuel filler neck breather hose, fuel tank vapour hose and the fuel tank harness installation position over the fuel tank assembly can be checked. 4.Disconnect the fuel filler neck breather hose, fuel tank vapour hose and the fuel tank harness connector. Then, remove the fuel tank assembly. 5.After removal of the fuel tank assembly, return the stabilizer bar to the original position, and install the clamp temporarily.

2.Place the fuel tank assembly on the transmission jack. 3.Raise the fuel tank to the position where the fuel filler neck breather hose, fuel tank vapour hose and the fuel tank harness connector can be connect. 4.Connect the fuel filler neck breather hose, fuel tank vapour hose and the fuel tank harness connector. 5.Use the transmission jack to install the fuel tank assembly to the vehicle. 6.Install the fuel tank band, and then tighten the fuel tank band mounting bolts and the fuel tank assembly mounting nuts to the specified torque and fix the fuel tank assembly. Tightening torque: 24 ± 4 N·m 7.After removal of the fuel tank assembly, return the stabilizer bar to the original position, and install the clamp. (Refer to GROUP 34 - Stabilizer Bar ).