REMOVAL AND INSTALLATION <6G7>

<SHORT WHEELBASE>

Fuel tank removal steps 1. Fuel tank under protector 2. Fuel filler hose connection <<A>> >>D<< 3. Fuel high-pressure tube connection 4. Fuel vapour hose connection <<B>> >>C<< 5. Fuel tank band, front <<B>> >>C<< 6. Fuel filler neck breather hose connection <<B>> >>C<< 7. Fuel tank harness connector connection <<B>> >>C<< 8. Fuel tank assembly

Fuel tank removal steps >>B<< 9. Fuel high-pressure tube 10. Fuel vapour hose 11. Fuel tank vapour hose 12. Fuel tank vapour hose 13. Fuel tank vapour hose 14. Fuel tank vapour hose 15. Fuel check valve 16. Fuel tank hose 17. Valve assembly 18. Packing 19. Fuel tank vapour hose 20. Fuel tank suction hose 21. Fuel tank harness 22. Retainer plate 23. Fuel tank pump module assembly 24. Packing <<C>> >>A<< 25. Fuel tank gauge unit 26. Packing 27. Fuel tank drain plug 28. Gasket 29. Fuel tank

Fuel filler neck removal steps 2. Fuel filler hose connection <<B>> >>C<< 6. Fuel filler neck breather hose connection 30. Fuel tank cap 31. Fuel filler neck protector 32. Fuel filler neck 33. Fuel filler neck gasket 34. Fuel filler hose 35. Fuel filler neck breather hose 36. Fuel filler neck pipe 37. Fuel filler neck breather hose 38. Shut-off valve

<LONG WHEELBASE (VEHICLES WITHOUT CANISTER)>

Fuel tank removal steps 1. Fuel tank under protector 2. Fuel filler hose connection <<A>> >>D<< 3. Fuel high-pressure tube connection <<B>> >>C<< 4. Fuel tank band, front <<B>> >>C<< 5. Fuel tank band, rear <<B>> >>C<< 6. Fuel filler neck breather hose connection <<B>> >>C<< 7. Fuel tank vapour hose connection <<B>> >>C<< 8. Fuel tank harness connector connection <<B>> >>C<< 9. Fuel tank assembly

Fuel tank removal steps >>B<< 10. Fuel high-pressure tube 11. Fuel tank vapour hose 12. Fuel hose connector 13. Fuel tank vapour hose 14. Valve assembly 15. Packing 16. Fuel tank suction hose 17. Fuel tank harness 18. Retainer plate 19. Fuel tank pump module assembly 20. Packing <<C>> >>A<< 21. Fuel tank gauge unit 22. Packing 23. Fuel tank drain plug 24. Gasket 25. Fuel tank

Fuel filler neck removal steps 2. Fuel filler hose connection <<B>> >>C<< 6. Fuel filler neck breather hose connection <<B>> >>C<< 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 38. Shut-off valve

<LONG WHEELBASE (VEHICLES WITH CANISTER)>

Fuel tank removal steps 1. Fuel tank under protector 2. Fuel filler hose connection <<A>> >>D<< 3. Fuel high-pressure tube connection 4. Fuel vapour hose connection <<B>> >>C<< 5. Fuel tank band, front <<B>> >>C<< 6. Fuel tank band, rear <<B>> >>C<< 7. Fuel filler neck breather hose connection <<B>> >>C<< 8. Fuel tank harness connector connection <<B>> >>C<< 9. Fuel tank assembly

Fuel tank removal steps >>B<< 10. Fuel high-pressure tube 11. Fuel vapour hose 12. Fuel tank vapour hose 13. Fuel tank vapour hose 14. Fuel tank vapour hose 15. Fuel tank vapour hose 16. Fuel check valve 17. Fuel tank hose 18. Valve assembly 19. Packing 20. Fuel tank vapour hose 21. Fuel tank suction hose 22. Fuel tank harness 23. Retainer plate 24. Fuel tank pump module assembly 25. Packing <<C>> >>A<< 26. Fuel tank gauge unit 27. Packing 28. Fuel tank drain plug 29. Gasket 30. Fuel tank

Fuel filler neck removal steps 2. Fuel filler hose connection <<B>> >>C<< 7. Fuel filler neck breather hose connection 31. Fuel tank cap 32. Fuel filler neck protector 33. Fuel filler neck 34. Fuel filler neck gasket 35. Fuel filler hose 36. Fuel filler neck breather hose 37. Fuel filler neck pipe 38. Fuel filler neck breather hose 39. Shut-off valve

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

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

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 and the fuel tank harness, lower the fuel tank assembly until the fuel filler neck breather 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.

caution After connecting the fuel high-pressure tube, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm. Connect the fuel high-pressure tube to the fuel tank module assembly.

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 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 ).

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

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