Fuel Tank: Service and Repair
Removal & Installation and Disassembly & Reassembly1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1 (W/ OFF ROAD PACKAGE)
a. Remove the 4 nuts, then remove the fuel tank protector.
4. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Remove the fuel pipe clamp.
b. Disconnect the fuel tank main tube and fuel tank return tube.
1. Pinch the retainer as illustrated, then pull the fuel tube connectors out of the pipes.
NOTE:
- Remove any dirt and foreign objects from the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
5. REMOVE FUEL TANK ASSEMBLY
a. Loosen the clamp bolt.
b. Disconnect the fuel breather tube.
1. Remove the checker of the fuel tube connector from the pipe.
2. Pinch the retainer of the fuel tube connector, then pull the tube connector out of the pipe.
NOTE:
- Remove any dirt and foreign objects from the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
c. Hold the fuel tank using the mission jack.
d. Remove the 2 fuel tank bands.
1. Remove the 2 bolts.
2. Remove the 2 clips and 2 pins, then remove the 2 fuel tank bands.
e. Slightly jack the fuel tank down and separate the fuel tank to filler pipe hose from the inlet pipe.
NOTE: Slowly jack down the fuel tank so as not to tear the wire harness and hose.
f. Disconnect the fuel pump connector.
g. Disconnect the fuel tank vent hose.
1. Pinch the retainer and pull the fuel tank vent hose connector out of the charcoal canister to disconnect the fuel tank vent hose from the charcoal canister.
NOTE:
- Remove any dirt and foreign objects from the fuel tank vent hose connector before performing this work.
- Do not allow any scratches of foreign objects on the parts when disconnecting, as the fuel tank vent hose connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent connector and pipe are stuck, push and pull to release them.
h. Remove the fuel tank assembly.
6. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Remove the 2 joint clips, then remove the fuel tank main tube and fuel tank return tube.
NOTE:
- Remove any dirt and foreign objects from the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.
7. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY
NOTE: Protect the connector and tube joint with masking tape or equivalent to prevent any foreign objects from sticking to them. Clean any dirt and foreign objects from the fuel suction tube assembly before removing.
a. Using a SST, loosen the retainer.
SST 09808- 14020 (09808- 01410, 09808- 01420, 09808-01430)
HINT: The ribs on the retainer can be fitted into a tip of the SST.
b. Remove the retainer.
c. Pull the fuel pump assembly out of the fuel tank.
NOTE: Be careful not to bend the arm of the sender gauge.
d. Remove the gasket from the fuel tank.
8. DRAIN FUEL
9. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Loosen the clamp bolt, then remove the fuel tank to filler pipe hose.
10. REMOVE FUEL TANK PROTECTOR NO.1
a. Remove the 4 clips, then remove the fuel tank protector.
11. INSTALL FUEL TANK PROTECTOR NO.1
a. Install the fuel tank protector with the 4 clips.
12. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Install the fuel tank onto the filler pipe hose, then tighten the pipe clamp bolt.
13. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSEMBLY
a. Install a new gasket onto the fuel tank.
b. Set the fuel pump assembly in the fuel tank.
NOTE: Be careful not to bend the arm of the sender gauge.
c. Fit a spline of the fuel suction tube assembly into a keyway of the fuel tank.
d. Install a new retainer.
1. Align the mark on a new retainer with the rib on the fuel tank as shown in the illustration.
2. Using SST, turn the retainer 740° to 780° clockwise (more than 2 turns), and position the mark on the retainer within range A to install it.
SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
HINT: The ribs on the retainer can be fitted into the tip of the SST.
14. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Install the fuel tank main tube and return tube with the 2 joint clips.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work.
- Check that the fuel tube joint is securely inserted to the end.
- Check that the tube joint clips are on the collar of the fuel tube joint.
- After installing the tube joint clip, check that the fuel tank main tube and return tube can be pulled out.
15. INSTALL FUEL TANK ASSEMBLY
a. Set the fuel tank assembly onto the mission jack.
b. Connect the fuel tank vent hose.
1. Align the fuel tank vent connector with the pipe, then push in the fuel tank vent connector until the retainer makes a click sound to connect the fuel tank vent hose to the fuel suction plate.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tank vent connector and plug before performing this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the quick connector.
c. Connect the fuel pump connector.
d. Connect the fuel tank to filler pipe hose.
e. Install the 2 fuel tank bands.
1. Install the 2 fuel tank bands with the 2 pins and 2 clips.
2. Install the 2 fuel tank bands with the 2 bolts.
Torque: 62 N.m (632 kgf.cm, 46 ft.lbf)
f. Connect the fuel tank breather tube.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound to connect the fuel tank vent breather tube.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank breather tube, check that the fuel pump tube is securely connected by pulling the fuel tube connector and pipe.
2. Install the checker onto the pipe.
g. Tighten the clamp bolt.
16. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Connect the fuel tank main tube and return tube.
1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound to connect the fuel tank main tube and return tube.
NOTE:
- Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
b. Install the fuel pipe clamp.
17. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1 (W/ OFF ROAD PACKAGE)
a. Install the fuel tank protector LWR with the 4 nuts.
Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
18. ADD FUEL
19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)
20. CHECK FOR FUEL LEAKAGE