REMOVAL AND INSTALLATION

Pre-removal Operation

Fuel Line Pressure Reduction [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Relay Disconnection (How to Reduce Pressurized Fuel Lines) <Except for Hong Kong and Singapore> ].
Fuel Line Pressure Reduction [Refer to GROUP 13B, On-vehicle Service - Fuel Pump Relay Disconnection (How to Reduce Pressurized Fuel Lines) <Vehicles for Hong Kong and Singapore> ].
Draining Fuel
Centre Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).

Post-installation Operation

Centre Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).
Refilling Fuel
Checking for Fuel Leaks

			Fuel tank assembly removal steps
		1.	Fuel filler hose connection <Fuel filler neck side>
		2.	Fuel filler neck breather hose connection <Fuel filler neck side>
		3.	Rear under cover (LH)
		4.	Rear under cover (RH)
		5.	Wiring harness clamp connection
		6.	Rear ABS sensor (LH) connector
		7.	Rear ABS sensor (RH) connector
<<A>>	>>C<<	8.	Fuel high-pressure hose connection
		9.	Fuel tank hose (vapour) connection
		10.	Fuel tank hose (return) connection
		11.	Connector clamp connection
<<B>>		12.	Wiring harness clamp connection
<<B>>		13.	Fuel tank pump and gauge assembly connector connection
<<B>>		14.	Fuel tank gauge unit connector connection
<<B>>		·	Fuel tank assembly
		15.	Fuel high-pressure hose
		16.	Fuel tank hose (return)
		17.	Fuel tank hose (vapour)
		18.	Fuel filler neck hose
		19.	Fuel filler neck breather hose
		20.	Fuel pump bracket plat
<<C>>	>>B<<	21.	Fuel tank pump and gauge assembly
		22.	Fuel tank pump gasket
<<C>>	>>A<<	23.	Fuel tank gauge unit
		24.	Fuel tank gauge unit gasket
		25.	Fuel tank clamp
		26.	Fuel tank lower protector
		27.	Fuel tank drain plug <Except for Hong kong, Singapore, Australia and New Zealand>
		28.	Gasket <Except for Hong kong, Singapore, Australia and New Zealand>
		29.	Fuel tank

			Fuel filler neck removal steps
		1.	Fuel filler hose connection <Fuel filler neck side>
		2.	Fuel filler neck breather hose connection <Fuel filler neck side>
		30.	Fuel tank cap
		·	Rear suspension crossmember stay (LH) (Refer to GROUP 34 - Rear Suspension Crossmember )
		31.	Fuel filler neck assembly
		32.	Fuel filler neck gasket
		33.	Fuel filler neck valve

REMOVAL SERVICE POINTS

<<A>> FUEL HIGH-PRESSURE HOSE DISCONNECTION

1.Push up the double lock of the fuel high-pressure hose connector.

2.Disconnect the fuel high-pressure hose while pushing the double lock of the fuel high-pressure hose connector.

<<B>> WIRING HARNESS CLAMP CONNECTION/FUEL TANK PUMP AND GAUGE ASSEMBLY CONNECTOR CONNECTION/FUEL TANK GAUGE UNIT CONNECTOR CONNECTION/FUEL TANK ASSEMBLY REMOVAL

caution

Be careful not to open circuit in the wiring harness when removing the fuel tank assembly.

1.Raise and support the fuel tank assembly with a transmission jack, and remove the mounting nuts.
2.Use a transmission jack while taking care of the wiring harness, and lower the fuel tank assembly until the wiring harness installation position of fuel tank assembly’s top can be made sure.
3.Remove the each wiring harness clamp connection, fuel tank pump and gauge assembly connector connection and fuel tank gauge unit connector connection, and then remove the fuel tank assembly.

<<C>> FUEL TANK PUMP AND GAUGE ASSEMBLY/FUEL TANK GAUGE UNIT REMOVAL

caution

When withdrawing the fuel tank pump and gauge assembly and the fuel tank gauge unit from the fuel tank, be careful not to damage the gauge and the float.

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

INSTALLATION SERVICE POINTS

>>A<< FUEL TANK GAUGE UNIT INSTALLATION

caution

When installing the fuel tank gauge unit into the fuel tank, be careful not to damage the gauge and the float.

>>B<< FUEL TANK PUMP AND GAUGE ASSEMBLY INSTALLATION

caution

When installing the fuel tank pump and gauge assembly from service hole to fuel tank, install it with suction hose mating mark facing as shown in the illustration not to twist the suction hose.
When installing the fuel tank pump and gauge assembly into the fuel tank, be careful not to damage the gauge and the float. In addition, be careful that the float of fuel gauge does not catch the suction hose in the fuel tank.
When installing the fuel tank pump and gauge assembly from service hole to fuel tank, make sure that the gauge moving area can move smoothly.

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

>>C<< FUEL HIGH-PRESSURE HOSE INSTALLATION

1.Before installing fuel high-pressure hose, push up the double lock of the fuel high-pressure hose connector.

2.Install the fuel high-pressure hose connector to the fuel line pipe, and push down the lock of the connector to lock it thoroughly.
3.After connecting the fuel high-pressure hose, slightly pull it to ensure that is installed securely. Also confirm that there is a play approximately 3 mm.