ТОПЛИВНЫЙ БАК (для моделей с длинной колесной базой) СНЯТИЕ

CAUTION / NOTICE / HINT

CAUTION:

The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

B0028WJ

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  3. REMOVE FUEL TANK CAP ASSEMBLY

  4. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. B0027CM

      Remove the 5 nuts and No. 1 fuel tank protector from fuel tank bands.

  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE


    1. B0026C6

      Slide the 2 clamps and disconnect the 2 fuel hoses from the fuel tank main tube sub-assembly and fuel tank return tube.

  6. DISCONNECT FUEL TANK BREATHER HOSE


    1. B0024PC

      for Type A:


      1. Detach the 2 clamps.

      2. Slide the clamp and disconnect the fuel hose and fuel tank breater hose from the fuel tank filler pipe sub-assembly.

    2. for Type B:


      1. Detach the clamp.

      2. B0026K5

        Slide the clamp and disconnect the fuel tank breater hose from the fuel tank filler pipe sub-assembly.

  7. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B002773

      Loosen the clamp and disconnect the fuel tank to filler pipe hose from the fuel tank filler pipe sub-assembly.

  8. REMOVE FUEL TANK ASSEMBLY

    CAUTION:

    The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.


    1. Using an engine lifter and attachments, support the fuel tank assembly.

    2. B0024UW

      Remove the 2 bolts and disconnect the 2 fuel tank bands.

    3. Remove the 2 clips, 2 fuel tank band pins and 2 fuel tank bands.

      Tech Tips

      Move the fuel tank assembly just enough to remove the fuel tank band pins.

    4. Slightly lower the engine lifter.

      Note

      Be careful not to cut the wire harness.

    5. B0028AYC01
      *1 Fuel Tank Cushion
      *2 Wire Harness
      *3 Fuel Tank Assembly

      Fold back approximately half of each fuel tank cushion so that the wire harness can be removed in the step below.

    6. B0027LV

      for Smart Cab:

      Detach the 3 claws and remove the fuel tank protector.

    7. B00294WC01
      *a Claw

      Detach the wire harness from the 6 clamps shown in the illustration.

    8. Disconnect the fuel sender gauge connector from the fuel tank vent tube assembly.

  9. REMOVE NO. 1 FUEL TANK HEAT INSULATOR


    1. B0028S7C01
      B0027PX Fuel Tank Bolt
      B0027QD Nut

      Remove the nut.

    2. Using needle-nose pliers, remove the 4 fuel tank bolts shown in the illustration, and then remove the No. 1 fuel tank heat insulator.

  10. REMOVE FUEL TANK CUSHION


    1. B00272IC01
      *1 Fuel Tank Cushion

      Remove the 2 fuel tank cushions from the fuel tank sub-assembly.

  11. REMOVE NO. 3 FUEL TUBE CLAMP


    1. B0027QU

      Detach the claw and remove the No. 3 fuel tube clamp.

  12. REMOVE FUEL TANK VENT TUBE ASSEMBLY


    1. B0026L6

      Remove the 2 tube joint clips and pull out the fuel tank main tube sub-assembly and fuel tank return tube from the fuel tank vent tube assembly.

      Note

      B00265CC01
      *a Fuel Tube Joint
      *b Fuel Tube
      *c O-Ring
      *d Tube Joint Clip

      • Remove any dirt and foreign matter on the fuel tube joint before performing this work.

      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      • Protect the disconnected parts by covering them with plastic bags and tape after disconnecting the fuel tank main tube sub-assembly and fuel tank return tube.

    2. Remove the fuel pump gauge retainer from the fuel tank assembly.


      1. B0028THC01
        *a SST (Plate)
        *b SST (Claw)
        *c Insertion point
        B0027PX SST (Bolt)

        Set the 2 claws and plate of SST on the fuel pump gauge retainer.

        SST
        09808-14031   ( 09808-01010, 09808-01020, 09808-01030 )
        09808-01071

        Tech Tips

        Securely insert the ends of SST into the insertion points in the fuel pump gauge retainer.

      2. While firmly pressing the claws of SST into the insertion points in the fuel pump gauge retainer, tighten the bolts of the claws.

      3. B002534C01
        *a Insertion point

        Attach the handle of SST.

      4. Check once more that the tip of SST is securely inserted into the insertion area of the fuel pump gauge retainer as shown in the illustration.

      5. While lightly pressing down on SST so it does not come off the fuel pump gauge retainer, slowly turn the handle and remove the fuel pump gauge retainer.

        Note


        • Do not use any tools other than SST, such as a screwdriver, etc.

        • Do not use excessive force when pressing down on SST, as the fuel pump gauge retainer will place excessive force on the fuel tank vent tube assembly and fuel pump gauge retainer and be difficult to remove, and parts may be damaged.

        • Be sure to keep the handle level when turning it, as SST may slip off the fuel pump gauge retainer if the handle is turned at an angle with excessive force.

        • Do not use an impact wrench or turn the handle with excessive force, as parts may be damaged.

        • If SST slips off the fuel pump gauge retainer, loosen the bolts and reattach SST to the fuel pump gauge retainer.

    3. Remove the fuel tank vent tube assembly from the fuel tank sub-assembly.

      Note

      Be careful not to bend the arm of the fuel sender gauge assembly.

    4. B00262U

      Remove the fuel tank vent tube gasket from the fuel tank sub-assembly.

  13. REMOVE FUEL TANK TO FILLER PIPE HOSE

    B0024PMC01
    *A for Type A
    *B for Type B

    1. for Type A:


      1. Loosen the clamp and remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.

      2. Remove the fuel hose from the fuel tank evaporation tube sub-assembly.

    2. for Type B:


      1. Loosen the clamp and remove the fuel tank to filler pipe hose from the fuel tank sub-assembly.

      2. Remove the No. 3 fuel tube joint from the fuel tank cut off valve.