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REMOVAL AND INSTALLATION


<FUEL TANK ASSEMBLY>


Pre-removal operation
  • Fuel Pump Connector Disconnection [Refer to GROUP 13B, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) .]
  • Fuel Draining.
  • Propeller Shaft Removal (Refer to GROUP 25, Propeller Shaft .)
  • Center Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe, Main Muffler and Catalytic Converter .)
  • Rear Seat Cushion Assembly Removal (Refer to GROUP 52A, Rear Seat Assembly .)

 Post-installation operation
  • Rear Seat Cushion Assembly Installation (Refer to GROUP 52A, Rear Seat Assembly .)
  • Center Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe, Main Muffler and Catalytic Converter .)
  • Propeller Shaft Installation (Refer to GROUP 25, Propeller Shaft .)
  • Fuel Refilling.
  • Fuel Leak Check.




Removal steps
<<A>>
1.
 Fuel pump module connector connection
<<A>>
2.
 Fuel tank differential pressure sensor connector connection
<<A>>
 >>C<<
 3.
 Fuel main pipe connection
<<A>>
4.
 Fuel return pipe connection
<<B>>
5.
 Fuel level sensor (sub) connector connection

>>B<<
 6.
 Hose clamp


7.
 Fuel leveling hose connection


8.
 Fuel tank vapor hose connection


9.
 Fuel tank vapor hose connection


10.
 Front floor under cover


11.
 Parking brake rear cable clamp connection
<<C>>
12.
 Fuel tank band
<<C>>
13.
 Fuel filler hose connection
<<C>>
14.
 Fuel tank assembly

<FUEL TANK FILLER TUBE ASSEMBLY>



Removal steps

>>B<<
 1.
 Hose clamp


2.
 Fuel filler hose connection


3.
 Fuel leveling hose connection


4.
 Fuel vapor hose connection


5.
 Fuel vapor hose connection
<<D>>
 >>A<<
 6.
 Rivet


7.
 Fuel filler hose protector


8.
 Fuel vapor tube connection


9.
 Fuel leveling pipe


10.
 Fuel tank filler tube breather hose


11.
 Fuel cap


12.
 Fuel tank filler tube assembly


13.
 Fuel tank filler tube boots

REMOVAL SERVICE POINTS

<<A>> FUEL PUMP MODULE CONNECTOR/FUEL TANK DIFFERENTIAL PRESSURE SENSOR CONNECTOR/FUEL MAIN PIPE/FUEL RETURN PIPE DISCONNECTION

1.Remove the floor inspection lid (LH.)

2.Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
3.Disconnect the fuel return hose.

4.Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe connector.

5.
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 angle to push up the retainer and unlock the fuel main pipe.
6.Disconnect the fuel main pipe from the fuel pump module.

<<B>> FUEL LEVEL SENSOR (SUB) REMOVAL

1.Remove the floor inspection lid (RH.)

2.Disconnect the fuel level sensor (sub) connector.

<<C>> FUEL TANK BAND/FUEL FILLER HOSE DISCONNECTION/FUEL TANK ASSEMBLY REMOVAL

1.Support the fuel tank assembly with a transmission jack to remove the connecting bolts of fuel tank band and the connecting nuts of fuel tank assembly.
2.Lower the transmission jack slightly and disconnect the fuel filler hose.
3.Tilt the fuel tank assembly, and remove the fuel tank assembly while avoiding the rear differential carrier.

<<D>> RIVET REMOVAL <FROM TO JUNE 2008>
caution Be careful not to score the heat protector by drill.

Use a 6.0 / diameter / mm drill to make a hole in the rivet to break it, and then remove the rivet.

INSTALLATION SERVICE POINTS

>>A<< RIVET INSTALLATION <FROM TO JUNE 2008>

Use a rivet tool shown in the illustration to connect the parts with rivets by the following procedures.
1.Insert the rivet into a corresponding location.
2.Set the rivet tool at a portion A of rivet.
3.While pushing the flange surface of the rivet onto parts to be fixed with the rivet tool, press the handle of the tool.
4.Thin part of portion A of the rivet will be cut off and the parts is fixed in position.

>>B<< HOSE CLAMP INSTALLATION

Connect the fuel filler hose, and tighten the bolt of hose clamp so that the bolt tightening dimension of the hose clump becomes 8.5 ± 1.5 mm (0.33 ± 0.06 inch.)

>>C<< FUEL MAIN PIPE CONNECTION

1.Before the installation, push up the retainer of the fuel main pipe connector.

2.Connect the connector of fuel main pipe to the fuel pump module securely.
3.
caution
  • When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
  • After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04inch) play.
Push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump module.