Note: For fuel level sensor and fuel pump replacement procedures, see "Fuel tank" chapters "fuel injection system (MPI)".
Removal and installation
− Before starting to remove parts, carry out the following operations:
- A) Drain the fuel from the tank.
- 6) Release residual pressure from the high pressure fuel line.
- V) Remove the center pipe of the exhaust system.
- G) (4WD Models) Remove the cardan shaft.
− Removal of parts is carried out in the order of the numbers indicated in the figures "Removing the fuel tank" And "Removing the fuel filler neck".
Removing the fuel tank. 1 - connection of the drain pipe and the filler neck of the fuel tank 2 - connection of the pipe of the fuel vapor recovery system 3 - connection of the fuel pipe 4 - connection of the fuel return pipe (Disconnect the left parking brake cable retainer, right rear wheel speed sensor harness retainer, and sensor harness connector), 5 - harness connector, 6 - fuel tank assembly, 7 - fuel hose, 8 - fuel return hose, 9 - fuel level sensor, 10 - gasket, 11 - fuel cutoff valve, 12 - gasket, 13 - cap, 14 - fuel pump assembly 15 - gasket, 16 - fuel vapor recovery system hose, 17 - check valve, 18 - fuel vapor recovery system pipe, 19 - fuel return pipe, 20 - fuel tank filler hose, 21 - drain hose.
Removing the filler neck of the fuel tank. 1 - filler hose connection, 2 - drain hose connection, 3 - fuel filler cap, 4 - fuel filler, 5 - fuel filler valve, 6 - seal.
− When removing the parts, pay attention to the operation to disconnect the fuel tank wiring harness connector.
Partially lower the fuel tank, then disconnect the harness connector.
- Installation is carried out in the reverse order of removal.
− When installing the parts, pay attention to the installation operation of the fuel hose.
To connect the fuel hose, push the hose connector onto the tube until the connector retainer catches the lug of the tube. Then lightly pull the connector in the direction of disconnection to make sure the connection is secure. Check that the play in the connection does not exceed 3 mm.
− After completing the installation of the parts, perform the following operations:
- A) (4WD Models) Install the cardan shaft.
- b) Install the center pipe of the exhaust system.
- V) Pour fuel into the tank.
- G) Check fuel line connections for leaks.
Examination
Note: The verification procedures are the same as the corresponding procedures in section "Fuel tank" chapters "fuel injection system (MPI)".
Disassembly and assembly of the fuel pump assembly
- Parts are removed in the order of the numbers shown in the figure "Disassembly of the fuel pump assembly".
Disassembly of the fuel pump assembly. 1 - cover, 2 - O-ring, 3 - fuel pump harness connector, 4 - bracket, 5 - buffer, 6 - fuel pump (low pressure), 7 - sealing sleeve, 8 - fuel pressure regulator (low pressure), 9 - O-ring, 10 - fuel filter assembly.
- Installation is carried out in the reverse order of removal.
− When installing the parts, pay attention to the installation procedure of the O-ring and the sealing sleeve.
Apply a small amount of fuel to the O-ring and grommet to prevent damage or twisting.