FUEL INJECTION (FUEL SYSTEMS)(H4DOTC DIESEL) > Fuel Tank

REMOVAL

WARNING:

Place “NO OPEN FLAMES” signs near the working area.

CAUTION:

Be careful not to spill fuel.

Catch the fuel from hoses using a container or cloth.

After disconnecting the quick connector, cover parts with a plastic bag to prevent dust and other foreign matter from getting into hoses and pipes.

1. Set the vehicle on a lift.

2. Disconnect the ground cable from battery.

3. Drain fuel from fuel tank.

4. Remove the rear seat.

5. Disconnect the fuel level sensor connector and remove the harness clamp holding it to the vehicle.

6. Push the grommet (B) down.

7. Remove the screw (A) and service hole cover.

8. Disconnect the fuel tube from the fuel level sensor.

CAUTION:

Be careful not to spill fuel.

Cover parts with a plastic bag to prevent dust and other foreign matter from getting in.

(A)

LHD model

(B)

RHD model

   

9. Remove the screw and remove the service hole cover of the fuel sub level sensor.

10. Disconnect the fuel tube from the fuel sub level sensor.

CAUTION:

Be careful not to spill fuel.

Cover parts with a plastic bag to prevent dust and other foreign matter from getting in.

11. Remove the rear wheels.

12. Remove the rear ABS wheel speed sensor from the rear housing.

13. Remove the bolt holding the rear brake hose bracket.

14. Remove the rear brake caliper and tie it to the body side of the vehicle.

15. Remove the parking brake cable from parking brake assembly.

16. Lift up the vehicle.

17. Remove the rear exhaust pipe.

18. Remove the propeller shaft.

19. Remove the heat shield cover and fuel tank protector.

20. Disconnect the connector from the rear ABS wheel speed sensor.

21. Remove the clamp and parking brake cable.

22. Remove the bolts securing the parking brake cable clamp.

23. Disconnect the connector, and then remove the nut to remove the rear vehicle height sensor. (left side only)

24. Separate the rear differential gear oil temperature switch connector and the ground connector, and remove the clamp from the rear sub frame.

25. Separate drain hose (B) from the drain connector (A).

26. Remove the rear suspension assembly.

WARNING:

Two persons are required to perform this procedure.

(1) Support the rear differential with the transmission jack.

(2) Remove the bolts which hold the rear shock absorber to the rear suspension arm.

(3) Remove the bolts which secure the rear suspension assembly to the body.

(4) Gradually lower the transmission jack and remove the rear suspension assembly.

27. Remove the heat shield cover.

28. Disconnect fuel filler hose (A) and air vent hose (B) from the fuel filler pipe assembly.

29. Disconnect the sub fuel pump harness connector (A).

30. Disconnect hose (B) from the sub fuel pump and fuel damper assembly.

31. Support the fuel tank with a transmission jack and remove the fuel tank.

WARNING:

Two persons are required to perform this procedure.

Fuel may be remaining in the fuel tank. This will cause the left and right sides to be unbalanced. Be careful not to drop the fuel tank when removing.

32. Disconnect the hoses from the fuel tank.

33. Disconnect the fuel delivery tube, fuel sub delivery tube and fuel return tube.

CAUTION:

Be careful not to spill fuel.

Cover quick connectors with a plastic bag to prevent dust and other foreign matter from getting in.

(A)

LHD model

(B)

RHD model

   

34. Disconnect the fuel level sensor and sub level sensor connectors, and remove the fuel harness.

35. Remove the clamps securing the fuel tubes and harnesses.

36. Remove the fuel level sensor and sub level sensor.

CAUTION:

Be careful not to spill fuel.

After removal, cover parts with a plastic bag to prevent dust and other foreign matter from getting in.

37. Remove the fuel tank band.