REMOVAL AND INSTALLATION


Pre-removal Operation
  • Fuel Draining (Refer to ).
  • Fuel Filler Neck Protector Removal (Refer to ).

 Post-installation Operation
  • Fuel Refilling.
  • Fuel Line Air Breeding <4N1>
  • Fuel Tank Check (Refer to ).
  • Fuel Filler Neck Protector Installation (Refer to ).

<4G6, 6B3>

Removal steps
<<A>>
 >>D<<
 1.
 Fuel high-pressure hose connection
<<A>>
 >>D<<
 2.
 Vapour hose connection


3.
 Fuel filler hose


4.
 Levelling hose
<<C>>
 >>B<<
 5.
 Self-locking nut
<<C>>
 >>B<<
 6.
 Fuel tank assembly
<<D>>
 >>A<<
 7.
 Fuel high-pressure hose


8.
 Vapour hose

<4N1>

Removal steps
<<B>>
 >>C<<
 1.
 Main hose connection
<<B>>
 >>C<<
 2.
 Return hose connection
<<B>>
 >>C<<
 3.
 Vapour hose connection


4.
 Fuel filler hose


5.
 Levelling hose


6.
 Vapour hose connection
<<C>>
 >>B<<
 7.
 Self-locking nut
<<C>>
 >>B<<
 8.
 Fuel tank assembly


9.
 Vapour hose

REMOVAL SERVICE POINTS

<<A>> FUEL HIGH-PRESSURE HOSE/VAPOUR HOSE DISCONNECTION

Carry out the procedures from the service hole (Refer to ).

<<B>> MAIN HOSE/RETURN HOSE/VAPOUR HOSE DISCONNECTION

Carry out the procedures from the service hole (Refer to ).

<<C>> SELF-LOCKING NUT/FUEL TANK ASSEMBLY REMOVAL

1.Support the fuel tank assembly using the transmission jack, and remove self-locking nuts of the fuel tank assembly.
2.Using the transmission jack while taking care of the fuel harness, lower the fuel tank assembly until the fuel harness installation position over the fuel tank assembly can be checked.
3.
caution Be careful not to open circuit in the harness when removing the fuel tank assembly.
Disconnect hoses, harness connector and harness clamp. Then, remove the fuel tank assembly.

<<D>> FUEL HIGH-PRESSURE HOSE REMOVAL

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

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

INSTALLATION SERVICE POINTS

>>A<< FUEL HIGH-PRESSURE HOSE CONNECTION

1.
caution After connecting the fuel high-pressure hose, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm.
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 securely, and push down the double lock of the connector to lock it thoroughly.

>>B<< FUEL TANK ASSEMBLY/SELF-LOCKING NUT INSTALLATION

1.Place the fuel tank assembly on the transmission jack.
2.Raise the fuel tank to the position where the hoses, harness connector and harness clamp can be assembled.
3.Assemble the hoses, harness connector and harness clamp.
4.Use the transmission jack to install the fuel tank assembly to the vehicle.

5.
caution When tightening the self-locking nut, be careful not to let the nut touch the bent part of the reinforcement of the fuel tank protector and the fuel tank.
Tighten a new self-locking nut to the specified torque and fix the fuel tank assembly.
Tightening torque: 55 ± 3 N·m

>>C<< VAPOUR HOSE/RETURN HOSE/MAIN HOSE CONNECTION
Carry out the procedures from the service hole (Refer to ).

>>D<< VAPOUR HOSE/FUEL HIGH-PRESSURE HOSE CONNECTION
Carry out the procedures from the service hole (Refer to ).