REMOVAL AND INSTALLATION <EXCEPT FOR BRAZIL AND CHILE>

Pre-removal Operation

Draining Fuel

Fuel Pump Connector Disconnection (How to Reduce Fuel Pressure) (Refer to GROUP 13A - On-vehicle Service ).

Centre Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).

Propeller Shaft Removal <4WD> (Refer to GROUP 25, Propeller Shaft ).

Post-installation Operation

Propeller Shaft Installation <4WD> (Refer to GROUP 25, Propeller Shaft ).

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
		3.	Main pipe connection
		4.	Return pipe
		5.	Fuel vapour pipe
		6.	Parking brake cable clamp connection (RH side)
		7.	Wiring harness clamp connection
		8.	Fuel tank gauge unit assembly, fuel tank pomp and gauge assembly connector connection
<<A>>		•	Rear differential support member installation nuts and bolts (Refer to GROUP 27 - Rear Differential Carrier Assembly ).
<<A>>		9.	Fuel tank assembly
	>>A<<	10.	Fuel high-pressure hose
		11.	Fuel return hose
		12.	Fuel tank hose
		13.	Fuel tank vapour hose 2way valve
		14.	Fuel vapour pipe
	>>A<<	15.	Fuel pump suction tube
<<B>>		16.	Fuel tank gauge unit
		17.	Gasket
		18.	Fuel tank safety valve
		19.	Gasket
		20.	Fuel pump bracket plate
<<B>>		21.	Fuel tank pump and gauge assembly
		22.	Fuel filler hose
		23.	Fuel filler neck breather hose
		24.	Fuel tank

			Fuel filler neck removal steps
		1.	Fuel filler hose connection <Fuel filler neck side>
		2.	Fuel filler neck breather hose connection
		26.	Fuel tank protector <4G63>
		27.	Fuel filler neck protector <4G64>
		28.	Fuel tank cap
		29.	Fuel filler neck
		30.	Fuel filler neck valve
		31.	Gasket

REMOVAL SERVICE POINTS

<<A>> REAR DIFFERENTIAL SUPPORT MEMBER INSTALLATION NUTS AND BOLTS/FUEL TANK ASSEMBLY REMOVAL

Remove the rear differential support member installation nuts and bolts, and then tilt the rear differential carrier assembly (Refer to GROUP 27 - Rear Differential Carrier Assembly ).

Raise and support the fuel tank assembly with a transmission jack, and remove the mounting nuts and bolts.

CAUTION

Support the fuel tank assembly securely so that it does not fall off from the transmission jack.

Tilt the fuel tank assembly to disconnect the connectors.

Remove the fuel tank assembly to the direction shown, being careful not to strike it against the rear differential carrier assembly.

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

CAUTION

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

INSTALLATION SERVICE POINS

>>A<< FUEL PUMP SUCTION TUBE/FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

After connecting the fuel high-pressure hose or fuel pump suction tube, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm.