REMOVAL AND INSTALLATION < VEHICLES 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 (Refer to GROUP 25, Propeller Shaft ).

Post-installation Operation

Propeller Shaft Installation (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.	Protector
		2.	Parking brake cable clamp connection (LH side)
	>>A<<	3.	Fuel high-pressure hose connection (Main pipe side)
		4.	Fuel return hose (Return pipe side)
		5.	Fuel filler hose, fuel filler neck breather hose, fuel tank hose connection (fuel filler neck side)
<<A>>		•	Rear differential support member installation nuts and bolts (Refer to GROUP 27 - Rear Differential Carrier Assembly ).
<<A>>		6.	Harness connector connection
<<A>>		7.	Fuel wiring harness connection
<<A>>		8.	Fuel tank assembly

			Fuel tank assembly removal steps
	>>A<<	9.	Fuel high-pressure hose
		10.	Fuel return hose
	>>A<<	11.	Fuel pump suction tube
		12.	Fuel pump bracket plate
<<B>>		13.	Fuel tank pump and gauge assembly
<<B>>		14	Fuel tank gauge unit
		15.	Gasket
		16.	Fuel tank temperature sensor unit
		17.	Gasket
		18.	Fuel filler neck breather hose
		19.	Levelling valve assembly
		20.	Gasket
		21.	Fuel tank hose
		22.	Fuel vapour pipe
		23.	Fuel tank vapour hose 2way valve
		24.	Fuel tank safety valve
		25	Gasket
		26.	Fuel tank hose
		27.	Fuel filler hose
		28.	Fuel filler neck valve
		29.	O-ring
		30.	Fuel tank

			Fuel filler neck removal steps
		5.	Fuel filler hose, fuel filler neck breather hose, fuel tank hose connection (fuel filler neck side)
		31.	Fuel vapour purge hose
		32.	Fuel vapour purge hose
		33.	Fuel vapour control purge hose
		34.	Fuel tank cap
		35.	Fuel filler neck protector
		36.	Fuel filler neck protector
		37.	Fuel filler neck
		38.	Gasket
		39.	Fuel filler neck hose
		40.	Fuel filler neck valve

REMOVAL SERVICE POINTS

<<A>> REAR DIFFERENTIAL SUPPORT MEMBER INSTALLATION NUTS AND BOLTS/HARNESS CONNECTOR CONNECTION/FUEL WIRING HARNESS CINNECTION/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.

Open the five harness clips and remove the fuel wiring harness from the fuel tank.

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

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