Fuel Tank: Service and Repair

Fuel Tank Assy (4WD) Part 1:

Fuel Tank Assy (4WD) Part 2:

Fuel Tank Assy (4WD) Part 3:

Fuel Tank Assy (4WD) Part 4:

FUEL TANK ASSY (4WD)
Removal & Installation and Disassembly & Reassembly

1. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY
2. REMOVE REAR FLOOR SERVICE HOLE COVER
3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
Refer to Fuel Pressure Release.

a. Start the engine.
b. After the engine has stopped on the its own, turn the ignition switch to lock.

4. REMOVE FUEL TANK PROTECTOR NO.2
5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. REMOVE FUEL PUMP ASSEMBLY
8. REMOVE FUEL SUCTION TUBE SET GASKET
9. DRAIN FUEL
10. REMOVE FRONT DOOR SCUFF PLATE RH
11. REMOVE COWL SIDE TRIM BOARD RH
12. REMOVE REAR DOOR SCUFF PLATE RH
13. REMOVE CENTER PILLAR GARNISH LOWER RH
14. REMOVE FRONT SEAT ASSY RH
15. REMOVE EXHAUST PIPE ASSY CENTER
a. Disconnect the oxygen sensor connector.
b. Remove the 2 exhaust pipe support.
c. Remove the bolt and clamp.







d. Remove the 2 bolts, 2 compression springs and exhaust pipe.


16. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY







17. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
Remove the 3 nuts and front floor heat insulator.







18. REMOVE FRONT FLOOR HEAT INSULATOR NO.2
Remove the 2 nuts and front floor heat insulator.







19. SEPARATE PARKING BRAKE CABLE ASSY NO.2
Remove the 3 installing bolts of the parking brake cable.







20. SEPARATE PARKING BRAKE CABLE ASSY NO.3
Remove the 3 installing bolts of the parking brake cable.







21. DISCONNECT CHARCOAL CANISTER OUTLET HOSE NO.1
Disconnect the charcoal canister outlet hose from the charcoal canister.







22. DISCONNECT FUEL TANK TO CANISTER TUBE
a. Disconnect the fuel tank to canister tube from the charcoal canister.
b. Remove the fuel tank to canister tube from the 2 evaporation vent tube clamps.







23. DISCONNECT FUEL EMISSION TUBE NO.2
a. Disconnect the fuel emission tube from the charcoal canister.
b. Remove the fuel tank to canister tube from the 2 evaporation vent tube clamps.








24. DISCONNECT FUEL EVAPORATION TUBE SUB-ASSY NO.1
Pinch the fuel tube connector clip and then pull out the fuel evaporation tube.

NOTE: Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.







Do not use any tool in this work.
Do not bend or twist the nylon tube by force.
After disconnecting, cover the fuel tube connector with a vinyl bag.
When the fuel tube connector and pipe are stuck, pinch the fuel evaporation tube between fingers, and turn it carefully to free and then disconnect the fuel evaporation tube.







25. DISCONNECT FUEL TANK VENT HOSE
Disconnect the fuel tank bent hose from the charcoal canister.

1. Push the connector deep inside.
2. Pinch portion A.
3. Pull out the connector.







26. REMOVE CHARCOAL CANISTER ASSY
a. Disconnect the pressure switching valve connector.
b. Remove the 3 bolts and charcoal canister.







27. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY
a. Pinch the fuel tube connector clip, and remove the fuel tube connector clip.
b. Pull out the fuel tank main tube.

NOTE: Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.







Do not use any tool in this work.
Do not bend or twist the nylon tube by force.
After disconnecting, cover the connector with a vinyl bag.
When the fuel tube connector and pipe are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.







28. DISCONNECT FUEL TANK INLET PIPE FUEL HOSE
Disconnect the fuel tank inlet pipe fuel hose from the fuel tank.







29. REMOVE FUEL TANK ASSY
a. Set a mission jack top the fuel tank.
b. Remove the 4 bolts and 2 fuel tank bands.
c. Operate the mission jack and then disconnect the 2 fuel tank breather hoses.







30. REMOVE FUEL TANK MAIN TUBE SUB-ASSY
Remove the fuel tank main tube from the fuel tube clamp.







31. REMOVE FUEL TUBE CLAMP NO.4
Remove the bolt and fuel tube clamp.







32. REMOVE FUEL TANK BREATHER HOSE
Remove the fuel breather hose from the fuel tank.







33. REMOVE FUEL EMISSION TUBE SUB-ASSY NO.1
Pinch the fuel tube connector clip and then pull out the fuel emission tube.

NOTE: Check if there is any dirt like mud around the fuel tube connector before this work and clean dirt away.
Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
Do not use any tool in this work.







Do not bend or twist the nylon tube by force.
After disconnecting, cover the fuel tube connector with a vinyl bag.
When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.







34. REMOVE EVAPORATION VENT TUBE CLAMP NO.2
Remove the bolt and evaporation vent tube clamp.







35. REMOVE CHECK VALVE PROTECTOR
Remove the 3 bolts and check valve protector.







36. REMOVE BREATHER TUBE SUB-ASSY
a. Pinch the fuel tube connector clip and then pull out the breather tube.

NOTE: Check if there is any dirt like mud around the connector before this work and clean dirt away.
Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
Do not use any tool in this work.







Do not bend or twist the nylon tube by force.
After disconnecting, cover the connector with a vinyl bag.
When the fuel tube connector and pipe are stuck, pinch the tube between fingers, and turn it carefully to free and then disconnect the tube.

b. Remove the breather tube from the Fuel tube bracket and clamp.







37. REMOVE FUEL TUBE BRACKET
Remove the fuel tube bracket from the fuel tank.







38. REMOVE FUEL TUBE CLAMP NO.2
Remove the fuel tube clamp from the fuel tank.







39. REMOVE FUEL TANK VENT HOSE
a. Disconnect the fuel tank bent hose from the charcoal canister.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull out the connector.

b. Remove the fuel tank vent hose from the fuel tube clamp.







40. REMOVE FUEL TUBE CLAMP NO.4
Remove the bolt and fuel tube clamp.








41. REMOVE FUEL TANK INLET VALVE ASSY
Remove the 3 bolt, check valve support and fuel tank inlet valve.







42. REMOVE CHECK VALVE GASKET
Remove the gasket from the fuel tank inlet valve.







43. REMOVE FUEL TANK PROTECTOR NO.1
Using a drill, cut the flange portion of the rivet.

HINT: Wind tape so that the drill blade appears approx. 5.0 mm (0.197 in.) on the edge.

NOTE: If the drill is pressed too firmly, the rivet will also rotate with the drill edge, thus flange will not be cut.
If the drill is pried against the rivet, the installation hole of the rivet may be cut or the drill blade may be damaged.
Use caution against the hot rivet after cut.







44. REMOVE FUEL TANK CUSHION NO.1
Remove the 10 fuel tank cushions from the fuel tank.







45. INSTALL FUEL TANK CUSHION NO.1
Install the 10 fuel tank cushions to the fuel tank.







46. INSTALL FUEL TANK PROTECTOR NO.1
Using a riveter, install the fuel tank protector with the 4 new rivet.

HINT: Install them with the rivet firmly pressed perpendicularly against the installation hole.

47. INSTALL CHECK VALVE GASKET
Install a new gasket to the fuel tank inlet valve.

48. INSTALL FUEL TANK INLET VALVE ASSY
Install the fuel tank inlet valve and check valve support with the 3 bolts.

Torque:.....................................3.5 N.m (36 kgf.cm, 31 in.lbf)

49. INSTALL FUEL TUBE CLAMP NO.4
Install the fuel tube clamp with the bolt.

Torque:.....................................6.0 N.m (61 kgf.cm, 53 in.lbf)

50. INSTALL BREATHER TUBE SUB-ASSY
Push in the breather tube to the pipe until fuel tube connector makes "click" sound.

NOTE: Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.

51. INSTALL CHECK VALVE PROTECTOR
Install the check valve protector with 3 bolts.

Torque:............................3.5 N.m (36 kgf.cm, 31 in.lbf)

52. INSTALL EVAPORATION VENT TUBE CLAMP NO.2
Install the evaporation vent tube clamp with the bolt.

Torque: ............................6.0 N.m (61 kgf.cm, 53 in.lbf)

53. INSTALL FUEL EMISSION TUBE SUB-ASSY NO.1
Push in the fuel emission tube to the pipe until fuel tube connector makes "click" sound.

NOTE: Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.

54. INSTALL FUEL TUBE CLAMP NO.4
Install the fuel tube clamp with the bolt.

Torque:.............................6.0 N.m (61 kgf.cm, 53 in.lbf)

55. INSTALL FUEL TANK ASSY
a. Set the mission jack to the fuel tank.
b. Operate the mission jack and then connect the 2 fuel tank breather hoses.
c. Install 2 fuel tank bands with the 4 bolts.

Torque:...........................39 N.m (400 kgf.cm, 29 ft.lbf)

56. CONNECT FUEL TANK MAIN TUBE SUB-ASSY
Push in the fuel tube connector to pipe until fuel tube connector, and install the fuel tube connector clip.

NOTE: Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.

57. INSTALL CHARCOAL CANISTER ASSY
a. Install the charcoal canister with 3 bolts.

Torque:............................19 N.m (194 kgf.cm, 14 ft.lbf)

b. Connect pressure switching valve connector.

58. CONNECT FUEL EVAPORATION TUBE SUB-ASSY NO.1
Push in the fuel evaporation tube to the pipe until fuel tube connector makes "click" sound.

NOTE: Check if there is any damage or foreign objects on the connected part.
After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.

59. INSTALL PARKING BRAKE CABLE ASSY NO.2
Install the parking brake cable with 3 bolts.

Torque:.............................5.4 N.m (55 kgf.cm, 48 in.lbf)

60. INSTALL PARKING BRAKE CABLE ASSY NO.3
Install the parking brake cable with 3 bolts.

Torque:...........................5.4 N.m (55 kgf.cm, 48 in.lbf)

61. INSTALL FRONT FLOOR HEAT INSULATOR NO.2
Install the front floor heat insulator with 2 nuts.

Torque:.....................................5.5 N.m (56 kgf.cm, 49 in.lbf)

62. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
Install the front floor heat insulator with 3 nuts.

Torque:...................................5.5 N.m (56 kgf.cm, 49 in.lbf)

63. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY

64. INSTALL EXHAUST PIPE ASSY CENTER
a. Using vernier calipers, measure the free length of the compression spring.

Free length:...................................40 mm (1.5748 in.)

b. Install a new gasket on the exhaust pipe front.
c. Install a new gasket on the exhaust pipe center (rear side).
d. Install the exhaust pipe center with the 2 compression springs, clamp and 3 bolts.


Torque:
Front ............................43 N.m (440 kgf.cm, 32 ft.lbf)
Rear.............................32 N.m (330 kgf.cm, 24 ft.lbf)

e. Install the 2 exhaust pipe supports.
f. Connect the oxygen sensor connector.

65. INSTALL FRONT SEAT ASSY RH
66. INSTALL FUEL SUCTION TUBE SET GASKET
67. INSTALL FUEL PUMP ASSEMBLY
68. INSTALL FUEL TANK VENT TUBE SET PLATE
69. CONNECT FUEL TANK MAIN TUBE SUB-ASSY
70. INSTALL FUEL TANK PROTECTOR NO.2
71. CHECK FUEL LEAK
72. CHECK EXHAUST GAS LEAK
73. INSTALL REAR FLOOR SERVICE HOLE COVER
74. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY