FUEL TANK REMOVAL


  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

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  2. DRAIN FUEL

  3. REMOVE FRONT CENTER FLOOR COVER


    1. A017BX6

      Remove the 4 bolts, 2 screws, and the nut.

    2. A017FB6

      Disengage the 4 clips and remove the center front floor cover.

  4. REMOVE TAIL EXHAUST PIPE ASSEMBLY


    1. A017DZ8

      Remove the 2 bolts and 2 compression springs.

    2. Disconnect the exhaust pipe support and remove the tail exhaust pipe assembly.

    3. Remove the gasket from the center exhaust pipe assembly.

  5. REMOVE CENTER EXHAUST PIPE ASSEMBLY


    1. A017EM8

      Remove the 2 bolts and 2 compression springs.

    2. Disconnect the 3 exhaust pipe supports and remove the center exhaust pipe assembly.

    3. Remove the gasket from the No. 3 exhaust pipe sub-assembly.

  6. REMOVE NO. 4 EXHAUST PIPE SUPPORT BRACKET


    1. A017DA3

      Remove the 2 bolts, and then remove the No. 4 exhaust pipe support bracket.

  7. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)


    1. A017FGM

      Depress the brake pedal and hold it.

    2. Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.

      Tech Tips

      Put a piece of cloth or equivalent into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover.

    3. A017FC7E01

      Place matchmarks on the rear propeller shaft and rear drive pinion flange sub-assembly.

    4. Remove the 4 nuts, 4 bolts and 4 washers.

    5. A017G71

      Remove the 4 bolts and 4 adjusting shims.

    6. A017DKO

      Using a brass bar and a hammer, remove the propeller shaft with center bearing shaft assembly.

    7. A017G8QE01

      Insert SST into the transfer to prevent oil leakage.

      SST
      09325-20010

  8. REMOVE REAR WHEELS (for 4WD)

  9. SEPARATE REAR SPEED SENSOR LH (for 4WD)


    1. A017FNS

      Remove the bolt and separate the rear speed sensor from the rear axle carrier sub-assembly.

      Note

      Keep the sensor tip and rear speed sensor installation hole free from foreign matter.

  10. SEPARATE REAR SPEED SENSOR RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  11. REMOVE REAR AXLE SHAFT NUT LH (for 4WD)


    1. A017CXTE01

      Using SST and a hammer, release the staked part of the rear axle shaft nut.

      SST
      09930-00010

      Note

      Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

    2. While applying the brakes, remove the rear axle shaft nut.

  12. REMOVE REAR AXLE SHAFT NUT RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  13. REMOVE REAR DISC BRAKE CALIPER ASSEMBLY LH (for 4WD)


    1. A017DLS

      Remove the 2 bolts and separate the rear disc brake caliper assembly.

      Note

      Use wire or an equivalent tool to keep the brake caliper from hanging down by the flexible hose.

  14. REMOVE REAR DISC BRAKE CALIPER ASSEMBLY RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  15. REMOVE REAR DISC (for 4WD LH Side)


    1. A017FKWE01

      Put matchmarks on the rear disc and the axle hub.

    2. A017DGC

      Release the parking brake and remove the rear disc.

      Tech Tips

      If the disc cannot be removed easily, turn and press firmly the shoe adjuster until the wheel comes free.

  16. REMOVE REAR DISC (for 4WD RH Side)

  17. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY LH (for 4WD)


    1. A017CXUE01

      Put matchmarks on the drive shaft and axle hub.

      Note

      Do not punch the marks.

    2. A017GBA

      Remove the 4 bolts and the rear axle hub and bearing assembly.

      Note


      • Do not rotate the drive shaft with the rear axle hub and bearing assembly removed.

      • Use wire or an equivalent tool to keep the parking brake assembly from hanging down by the parking brake cable assembly.

  18. REMOVE REAR AXLE HUB AND BEARING ASSEMBLY RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  19. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY (for 4WD)


    1. A017DVV

      Remove the bolt and the nut, and separate the No. 3 parking brake cable assembly.

  20. REMOVE NO. 2 PARKING BRAKE CABLE ASSEMBLY (for 4WD)

    Tech Tips

    Perform the same procedure as the No. 3 parking brake cable assembly.

  21. REMOVE REAR STRUT ROD ASSEMBLY LH (for 4WD)


    1. A017C6R

      Remove the 2 bolts, the 2 nuts, and the rear strut rod assembly.

      Note

      Since stopper nuts are used, loosen the bolts.

  22. REMOVE REAR STRUT ROD ASSEMBLY RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  23. REMOVE REAR AXLE CARRIER SUB-ASSEMBLY LH (for 4WD)


    1. A017DVS

      Loosen the 2 bolts.

      Note

      Since stopper nuts are used, loosen the bolts.

    2. A017F92

      Remove the 2 bolts and 2 nuts, and separate the rear shock absorber with coil spring (lower side) from the rear axle carrier sub-assembly.

      Note


      • Be careful not to damage the outboard joint boot.

      • Be careful not to damage the speed sensor rotor.

    3. A017B48

      Remove the 2 bolts, the 2 nuts, and the rear axle carrier sub-assembly.

      Note


      • Be careful not to damage the outboard joint boot.

      • Be careful not to damage the speed sensor rotor.

      Tech Tips

      Use wire or an equivalent tool to keep the rear drive shaft assembly from hanging down.

  24. REMOVE REAR AXLE CARRIER SUB-ASSEMBLY RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  25. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (for 4WD)

    A017B9QE01

    1. Put matchmarks on the adjust cams and the rear suspension member sub-assembly.

    2. Remove the nut, the No. 2 camber adjust cam, the rear suspension toe adjust cam sub-assembly, and the rear No. 2 suspension arm assembly LH.

      Note

      Mark the removed parts to distinguish left from right and keep them in order for reinstallation.

      Tech Tips

      When removing the nut, keep the rear suspension toe adjust cam sub-assembly from rotating.

  26. REMOVE REAR NO. 2 SUSPENSION ARM ASSEMBLY RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  27. REMOVE REAR NO. 1 SUSPENSION ARM ASSEMBLY RH (for 4WD)

    A017BH0

    1. Remove the bolt, the nut, and the rear No. 1 suspension arm assembly RH from the rear suspension member sub-assembly.

      Note


      • Since a stopper nut is used, loosen the bolt.

      • Mark the removed parts to distinguish left from right and keep them in order for reinstallation.

  28. REMOVE REAR DIFFERENTIAL FILLER PLUG (for 4WD)


    1. A017CDX

      Using a hexagon wrench (10 mm), remove the rear differential filler plug and rear differential filler plug gasket.

  29. REMOVE REAR DIFFERENTIAL DRAIN PLUG (for 4WD)


    1. A017B3M

      Using a hexagon wrench (10 mm), remove the rear differential drain plug and rear differential drain plug gasket, and drain the oil.

  30. REMOVE REAR DRIVE SHAFT ASSEMBLY LH (for 4WD)


    1. A017GATE01

      Using SST, remove the rear drive shaft assembly as shown in the illustration.

      SST
      09520-01010
      09520-24010   ( 09520-32040 )

      Note

      Remove the rear drive shaft assembly while keeping it level.

  31. REMOVE REAR DRIVE SHAFT SNAP RING LH (for 4WD)


    1. A017BTQE04

      Using a screwdriver, remove the rear drive shaft snap ring.

  32. REMOVE REAR DRIVE SHAFT ASSEMBLY RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  33. REMOVE REAR DRIVE SHAFT SNAP RING RH (for 4WD)

    Tech Tips

    Perform the same procedure as the LH side.

  34. REMOVE REAR SUSPENSION MEMBER (for 4WD)


    1. A017C3RE01

      Support the rear suspension member with a jack using a wooden block.

      Tech Tips

      Use a properly sized wooden block to keep the jack and suspension member level.

    2. A017F1OE01

      Remove the 4 nuts, 2 bolts and 2 rear lower suspension member stopper retainers.

    3. Lower the rear suspension member.

    4. Remove the 2 rear upper suspension member stoppers.

  35. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. A017ED7E01

      Remove the 3 clips (A) and 7 nuts, and then remove the No. 1 fuel tank protector sub-assembly.

  36. REMOVE FUEL TANK ASSEMBLY


    1. A017BH3E01

      Disconnect the fuel pump tube.


      1. Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.

      2. Pull out the fuel pump tube.

        Note


        • Check if there is any dirt or mud around the connector before this operation and clean the connector if necessary.

        • It is necessary to prevent mud or dirt from entering the quick connector. If any foreign objects enter the connector, the O-rings may seal properly.

        • Do not use any tool in this operation.

        • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.

        • When the pipe and connector are stuck, push and pull the connector to release it and pull the connector out carefully.

    2. A017FL9

      Disconnect the fuel tank vent hose.


      1. Slide the clamp and disconnect the fuel tank vent hose.

    3. A017DQKE02

      Disconnect the No. 3 fuel tank breather tube.


      1. Loosen the hose clamp bolt and disconnect the No. 3 fuel tank breather tube.

    4. A017FXOE02

      Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.

    5. Set a transmission jack under the fuel tank.

    6. Remove the 4 bolts, and then remove the 2 fuel tank bands.

    7. Remove the 2 nuts.

    8. Operate the transmission jack to remove the fuel tank.

      A017B4C

  37. REMOVE REAR FUEL TANK SIDE PLATE


    1. A017C1G

      Remove the rear fuel tank side plate.

  38. REMOVE NO. 1 FUEL TANK CUSHION


    1. A017CJ7

      Remove the No. 1 fuel tank cushion.

  39. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY


    1. A017ENGE01

      Release the 2 claws, and then remove the fuel pump tube.

  40. REMOVE FUEL TANK TO FILLER PIPE HOSE


    1. A017BHA

      Loosen the hose clamp bolt, and then remove the fuel tank to filler pipe hose.

  41. REMOVE TANK SUCTION TUBE SUPPORT


    1. A017GA5

      Remove the tank suction tube support from the fuel tank.

  42. REMOVE FUEL TANK SIDE PLATE


    1. A017CJ6E01

      Remove the bolt and nut, and then remove the fuel tank side plate and the fuel tank bracket.

  43. REMOVE FUEL TANK CUSHION SET


    1. A017B4NE01

      Remove the 2 fuel tank cushion sets and 2 No. 5 fuel tank cushions.