REMOVAL AND INSTALLATION <4B1, 6B3>


Pre-removal operation
  • Second Seat Assembly Removal (Refer to GROUP 52A - Second Seat Assembly).
  • Fuel Line Pressure Reduction (Refer to GROUP 13A - On-vehicle Service, Reduce Pressurized Fuel Lines <4B1>, GROUP 13B - On-vehicle Service, Reduce Pressurized Fuel Lines <6B3>).
  • Draining Fuel
  • Propeller Shaft Assembly Removal (Refer to GROUP 25 - Propeller Shaft).
  • Exhaust Centre Pipe Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler).

 Post-installation operation
  • Exhaust Centre Pipe Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler).
  • Propeller Shaft Assembly Installation (Refer to GROUP 25 - Propeller Shaft).
  • Refilling Fuel
  • Checking for Fuel Leaks
  • Second Seat Assembly Installation (Refer to GROUP 52A - Second Seat Assembly).




Removal steps
<<A>>
1.
 Fuel pump and gauge assembly connector
<<A>>
 >>B<<
 2.
 Fuel main pipe connection
<<B>>
3.
 Fuel gauge unit connector


4.
 Fuel vapour pipe connection


5.
 Front floor under cover

>>A<<
 6.
 Fuel filler hose


7.
 Fuel shut-off valve


8.
 Fuel filler neck breather hose


·
 Parking brake rear cable clamp connection (Refer to GROUP 36 - Parking Brake Cable <Lever type parking brake>).


·
 Electric parking brake harness assembly clamp connection and bracket connection (Refer to GROUP 36 - Electric Parking Brake Actuator ).
<<C>>
·
 Differential mount bracket mounting bolt (Refer to GROUP 27B - Differential Carrier Assembly).
<<C>>
9.
 Fuel tank band
<<C>>
10.
 Fuel tank assembly


11.
 Fuel tank cap


12.
 Fuel filler neck assembly


13.
 Fuel vapour hose

REMOVAL SERVICE POINTS

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

1.Remove the floor inspection lid (LH).

2.Disconnect the fuel pump and gauge assembly 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 pump and gauge assembly.

<<B>> FUEL GAUGE UNIT CONNECTOR DISCONNECTION

1.Remove the floor inspection lid (RH).

2.Disconnect the fuel gauge unit connector.

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

1.Remove the fuel tank, continuously checking that it does not make contact with the 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.

INSTALLATION SERVICE POINTS

>>A<< FUEL FILLER HOSE CONNECTION

After connecting the fuel filler hose, tighten the bolts of hose clamp so that the tightening dimension is 4.5 ± 1.5 mm.

>>B<< 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 pump and gauge assembly securely and push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump and gauge assembly.