13C-1

GROUP 13C

FUEL SUPPLY
CONTENTS

GENERAL INFORMATION . . . . . . . . 13C-2 FUEL TANK GAUGE UNIT REPLACEMENT

<4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-5
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13C-2
FUEL TANK . . . . . . . . . . . . . . . . . . . . 13C-7
ON-VEHICLE SERVICE. . . . . . . . . . . 13C-2 REMOVAL AND INSTALLATION <4G63> . 13C-7
FUEL PUMP OPERATION CHECK . . . . . . 13C-2 REMOVAL AND INSTALLATION <4G69> . 13C-11
FUEL GAUGE UNIT CHECK . . . . . . . . . . . 13C-2 FUEL PUMP ASSEMBLY DISASSEMBLY
AND REASSEMBLY <2WD> . . . . . . . . . . . 13C-14
FUEL PUMP ASSEMBLY <2WD>,
FUEL TANK PUMP AND GAUGE ASSEMBLY
FUEL TANK PUMP AND GAUGE ASSEMBLY
<4WD> REPLACEMENT . . . . . . . . . . . . . . 13C-2 DISASSEMBLY AND REASSEMBLY
<4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-15
FUEL TANK GAUGE UNIT REPLACEMENT
<2WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-4 FUEL TANK GAUGE UNIT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 13C-16
13C-2 FUEL SUPPLY
GENERAL INFORMATION

GENERAL INFORMATION
M1135000100457
• The fuel tank is located under the floor of the rear • A fuel pump assembly <2WD>, fuel pump and
seats to provide increased protection and a more gauge assembly <4WD> including fuel pump,
luggage space. fuel filter, reservoir and fuel gauge unit, has been
• A fuel tank safety valve assembly has been adopted to lighten weight and improve
adopted to prevent fuel from leaking out in case serviceability.
of a collision.

SEALANT
M1135005200039

Item Specified sealant

Service hole cover and floor pan <2WD> 3Mä 8513 Grommets windshield sealer (Black)

ON-VEHICLE SERVICE
FUEL PUMP OPERATION CHECK 2. Remove the service hole cover mounting screws
M1135001000174 and remove the service hole cover.
<4G63>: Refer to GROUP 13A - On-vehicle Service,
Fuel Pump Operation Check P.13A-328. Fuel pump assembly <2WD>
<4G69>: Refer to GROUP 13B - On-vehicle Service, or fuel tank pump and gauge assembly <4WD>
Fuel Pump Operation Check P.13B-428. connector

FUEL GAUGE UNIT CHECK

M1135003100371 Fuel suction
Refer to GROUP 54A − Combination Meter, tube <4WD>
On-vehicle Service, Fuel Gauge Unit Check
P.54A-69 <2WD>, P.54A-70 <4WD>.

FUEL PUMP ASSEMBLY <2WD>, FUEL

TANK PUMP AND GAUGE ASSEMBLY
<4WD> REPLACEMENT
M1135004900336
1. Remove the rear seat cushion assembly (Refer to
GROUP 52A − Rear seat assembly P.52A-36).
Service hole cover

Fuel return hose

<4G63> Fuel high-pressure
hose
AC309286AB

3. Disconnect the fuel pump assembly <2WD> or

fuel tank pump and gauge assembly <4WD>
connector, fuel return hose, fuel high-pressure
AC102784 AB
hose and fuel suction tube <4WD>.
 FUEL SUPPLY
ON-VEHICLE SERVICE
13C-3
CAUTION CAUTION
Fuel tank pump and
gauge assembly
Corresponding side
Fuel high-pressure hose or
fuel pump suction tube <4WD>
Service hole

Float
3 mm
Quick connector
AC107193AC AC300047AC

For 4WD: Pay attention not to damage the float After connecting the fuel high-pressure hose or
when removing and installing fuel tank pump and fuel pump suction tube <4WD>, slightly pull it to
gauge assembly through the service hole. ensure that it is installed securely. Also confirm
4. Remove the mounting nuts and fuel pump bracket that there is a play approximately 3 mm.
plate, and remove the fuel pump assembly Fuel pump assembly <2WD>
<2WD>, fuel tank pump and gauge assembly or fuel tank pump and gauge assembly <4WD>
<4WD> from the service hole. connector
5. Install the fuel pump assembly <2WD>, fuel tank
pump and gauge assembly <4WD> to the fuel
Fuel suction
tank through the service hole.
tube <4WD>
Fuel pump braket plate

2.5 ± 0.4 N·m

AC107194AC

6. Install the fuel pump bracket plate to the fuel tank

and tighten the mounting nuts to the specified Fuel return hose
<4G63> Fuel high-pressure
torque. hose
Tightening torque: 2.5 ± 0.4 N⋅m AC309286AB

7. Connect the fuel pump assembly <2WD> or fuel

tank pump and gauge assembly <4WD>
connector, fuel return hose, fuel high-pressure
hose and fuel suction tube <4WD>.
Service hole cover

AC102784 AB
13C-4 FUEL SUPPLY
ON-VEHICLE SERVICE

8. Tighten the service hole cover mounting screws CAUTION

and install the service hole cover. Fuel tank gauge unit
9. Install the rear seat cushion assembly. (Refer to
GROUP 52A − Rear seat assembly P.52A-36).

FUEL TANK GAUGE UNIT

REPLACEMENT <2WD> Gauge unit
M1135001400398
1. Remove the rear seat cushion assembly (Refer to
GROUP 52A − Rear Seat Assembly P.52A-36).
Flat-tipped screwdriver Service hole AC107188AD

Pay attention not to damage the gauge unit and

the float of the fuel tank gauge unit when
withdrawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts
and remove the fuel tank gauge unit from service
hole.
CAUTION
Service hole cover AC107600AC
Fuel tank gauge unit
2. Pry off the service hole cover using a flat-tipped
screwdriver, etc.
Fuel tank gauge unit
Gauge unit

Service hole AC107188AE

Pay attention not to damage the gauge unit and

the float of the fuel tank gauge unit when
Fuel tank gauge unit
harness connector AC107601AC inserting it from the service hole.

3. Disconnect the fuel tank gauge unit harness 2.5 ± 0.4 N·m
connector.

AC107602 AC

5. Install the fuel tank gauge unit to the fuel tank

through the service hole, and tighten the mounting
nuts to the specified torque.
Tightening torque: 2.5 ± 0.4 N⋅m
 FUEL SUPPLY
ON-VEHICLE SERVICE
13C-5
Fuel tank gauge unit Service hole cover

Fuel tank gauge unit

harness connector AC107601AC AC107603AC

6. Connect the fuel tank gauge unit harness 2. Remove the service hole cover mounting screws
connector. and remove the service hole cover.
Fuel pump suction tube

Service hole cover

Fuel tank gauge unit

Floor pan Fuel tank gauge

unit harness
connector
AC100961AD AC107189AC

7. Apply the specified sealant to the contact surfaces 3. Disconnect the fuel tank gauge unit harness
of the service hole cover and the floor pan, and connector and fuel pump suction tube.
install the service hole cover. CAUTION
Specified sealant: 3Mä 8513 Grommets
Windshield Sealer (Black)
8. Install the rear seat cushion assembly (Refer to
GROUP 52A − Rear Seat Assembly P.52A-36). Gauge unit
Fuel tank gauge unit
FUEL TANK GAUGE UNIT
REPLACEMENT <4WD> Service hole
M1135001400406
1. Remove the rear seat cushion assembly (Refer to
GROUP 52A − Rear Seat Assembly P.52A-36). Float
AC107190AD

Pay attention not to damage the gauge unit and

the float of the fuel tank gauge unit when
withdrawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts
and remove the fuel tank gauge unit from service
hole.
13C-6 FUEL SUPPLY
ON-VEHICLE SERVICE

CAUTION CAUTION

Main pipe nozzle or

fuel main pipe
Gauge unit
Fuel high-pressure hose or
Fuel tank gauge unit fuel pump suction tube
Service hole

3 mm
Float Quick connector
AC107190 AE AC300047AB

Pay attention not to damage the gauge unit and After connecting the fuel high-pressure hose or
the float of the fuel tank gauge unit when fuel pump suction tube, slightly pull it to ensure
inserting it from the service hole. that it is installed securely. Also confirm that
there is a play approximately 3 mm.
2.5 ± 0.4 N·m
Fuel pump suction tube

Fuel tank gauge unit

Fuel tank gauge

unit harness
AC107618AC
connector
AC107189AC
5. Install the fuel tank gauge unit to the fuel tank
through the service hole, and tighten the mounting 6. Connect the fuel tank pump gauge unit harness
nuts to the specified torque. connector and fuel suction tube.
Tightening torque: 2.5 ± 0.4 N⋅m Service hole cover

AC107603AC

7. Tighten the service hole cover mounting screws

and install the service hole cover.
8. Install the rear seat cushion assembly (Refer to
GROUP 52A − Rear Seat Assembly P.52A-36).
 FUEL SUPPLY
FUEL TANK
13C-7
FUEL TANK
REMOVAL AND INSTALLATION <4G63>
M1135001900520

Pre-removal Operation Post-installation Operation

• Draining Fuel • Propeller Shaft Installation <4WD> (Refer to GROUP 25,
• Fuel Pump Connector Disconnection (How to Reduce Propeller Shaft P.25-3).
Fuel Pressure) (Refer to GROUP 13A − On-vehicle • Centre Exhaust Pipe Installation (Refer to GROUP 15,
Service P.13A-328). Exhaust Pipe and Main Muffler P.15-13).
• Centre Exhaust Pipe Removal (Refer to GROUP 15, • Refilling Fuel
Exhaust Pipe and Main Muffler P.15-13). • Checking for Fuel Leaks
• Propeller Shaft Removal <4WD> (Refer to GROUP 25,
Propeller Shaft P.25-3).

<2WD>
8
2.5 ± 0.4 N·m

21
11
8 2.5 ± 0.4 N·m 12
5
15 13
13 15 13
17 22
18 N
2.5 ± 0.4 N·m 4 3
20 N 19
20 N 19
9 2.5 ± 0.4 N·m 13 24 2
14 13

25

1
23
6

26 ± 4 N·m

26 ± 4 N·m 7
AC212356 AB
13C-8 FUEL SUPPLY
FUEL TANK

<4WD>
8
2.5 ± 0.4 N·m

2.5 ± 0.4 N·m 21

16 11
8 12
2.5 ± 0.4 N·m 13 5
15
13 15 13
22
17 N 18 2.5 ± 0.4 N·m
4 3
13 20 N
20 N 19 14 19
13 2
24
10

25 1
23

26 ± 4 N·m 7 AC212516AB

Fuel tank assembly removal Fuel tank assembly removal

steps steps (Continued)
1. Fuel filler hose connection <Fuel >>A<< 11. Fuel high-pressure hose
filler neck side> 12. Fuel return hose
2. Fuel filler neck breather hose 13. Fuel tank hose
connection <Fuel filler neck side> 14. Fuel tank vapour hose 2way valve
3. Main pipe connection 15. Fuel vapour pipe
4. Return pipe >>A<< 16. Fuel pump suction tube <4WD>
5. Fuel vapour pipe <<B>> 17. Fuel tank gauge unit
6. Parking brake cable clamp 18. Gasket
connection <RH side> 19. Fuel tank safety valve
7. Wiring harness clamp connection 20. Gasket
8. Fuel tank gauge unit assembly, fuel 21. Fuel pump bracket plate
pump assembly <2WD>, fuel tank <<B>> 22. Fuel pump assembly <2WD>, fuel
pomp and gauge assembly <4WD> tank pump and gauge assembly
connector connection <4WD>
<<A>> • Rear differential support member 23. Fuel filler hose
installation nuts and bolts <4WD> 24. Fuel filler neck breather hose
(Refer to GROUP 27B − Rear 25. Fuel tank
Differential Carrier Assembly
P.27B-16).
9. Fuel tank assembly <2WD>
<<A>> 10. Fuel tank assembly <4WD>
 FUEL SUPPLY
FUEL TANK
13C-9

<FUEL FILLER NECK>

30

27
28

29

1
26

AC300410AB

Fuel filler neck removal steps Fuel filler neck removal steps
1. Fuel filler hose connection <Fuel 27. Fuel tank cap
filler neck side> 28. Fuel filler neck
2. Fuel filler neck breather hose 29. Fuel filler neck valve
connection <Fuel filler neck side> 30. Gasket
26. Fuel filler neck protector
13C-10 FUEL SUPPLY
FUEL TANK

REMOVAL SERVICE POINTS CAUTION

<<A>> REAR DIFFERENTIAL SUPPORT Support the fuel tank assembly securely so that
MEMBER INSTALLATION NUTS AND BOLTS it does not fall off from the transmission jack.
<4WD>/FUEL TANK ASSEMBLY <4WD> 3. Tilt the fuel tank assembly to disconnect the
REMOVAL connectors.
Rear differential
Fuel tank assembly Towards front Rear differential
carrier assembly of vehicle carrier assembly

Tilt
Towards front
of vehicle AC300033AB
Lower
Fuel tank assembly AC300043AB

1. Remove the rear differential support member 4. Remove the fuel tank assembly to the direction
installation nuts and bolts, and then tilt the rear shown, being careful not to strike it against the
differential carrier assembly (Refer to GROUP rear differential carrier assembly.
27B − Rear Differential Carrier Assembly
P.27B-16). <<B>> FUEL TANK GAUGE UNIT/FUEL PUMP
ASSEMBLY <2WD>, FUEL TANK PUMP AND
GAUGE ASSEMBLY <4WD> REMOVAL
CAUTION
When withdrawing the fuel tank gauge unit, fuel
tank pump and gauge assembly from the fuel
tank, be careful not damage the module unit and
the float.

Fuel tank assembly INSTALLATION SERVICE POINS

Transaxle jack AC107196 AD >>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL
HIGH-PRESSURE HOSE INSTALLATION
2. Raise and support the fuel tank assembly with a
transmission jack, and remove the mounting nuts CAUTION
and bolts.
Towards front
of vehicle Rear differential Corresponding side
Fuel tank assembly carrier assembly
Fuel high-pressure hose or
fuel pump suction tube <4WD>

3 mm
Quick connector
AC300047AC
Tilt
AC300040AB After connecting the fuel high-pressure hose or
fuel pump suction tube <4WD>, slightly pull it to
ensure that it is installed securely. Also confirm
that there is a play approximately 3 mm.
 FUEL SUPPLY
FUEL TANK
13C-11
REMOVAL AND INSTALLATION <4G69>
M1135001900542

Pre-removal Operation Post-installation Operation

• Draining Fuel • Propeller Shaft Installation (Refer to GROUP 25,
• Fuel Pump Connector Disconnection (How to Reduce Propeller Shaft P.25-3).
Fuel Pressure) (Refer to GROUP 13B − On-vehicle • Centre Exhaust Pipe Installation (Refer to GROUP 15,
Service P.13B-428). Exhaust Pipe and Main Muffler P.15-13).
• Centre Exhaust Pipe Removal (Refer to GROUP 15, • Refilling Fuel
Exhaust Pipe and Main Muffler P.15-13). • Checking for Fuel Leaks
• Propeller Shaft Removal (Refer to GROUP 25, Propeller
Shaft P.25-3).

7
2.5 ± 0.4 N·m

2.5 ± 0.4 N·m 18

13
9
7
4
2.5 ± 0.4 N·m 10
12
10 12 10 19
N 15 2.5 ± 0.4 N·m
14 3

10 17 N 16
17 N 16 11
10 2
21
8

22 1
20

26 ± 4 N·m
6 AC309122AB

Fuel tank assembly removal Fuel tank assembly removal

steps steps (Continued)
1. Fuel filler hose connection <Fuel <<A>> • Rear differential support member
filler neck side> installation nuts and bolts (Refer to
2. Fuel filler neck breather hose GROUP 27B − Rear Differential
connection <Fuel filler neck side> Carrier Assembly P.27B-16).
3. Main pipe connection <<A>> 8. Fuel tank assembly
4. Fuel vapour pipe >>A<< 9. Fuel high-pressure hose
5. Parking brake cable clamp 10. Fuel tank hose
connection <RH side> 11. Fuel tank vapour hose 2way valve
6. Wiring harness clamp connection 12. Fuel vapour pipe
7. Fuel tank gauge unit assembly, fuel >>A<< 13. Fuel pump suction tube
tank pomp and gauge assembly <<B>> 14. Fuel tank gauge unit
connector connection 15. Gasket
16. Fuel tank safety valve
13C-12 FUEL SUPPLY
FUEL TANK

Fuel tank assembly removal

steps (Continued)
17. Gasket
18. Fuel pump bracket plate
<<B>> 19. Fuel tank pump and gauge
assembly
20. Fuel filler hose
21. Fuel filler neck breather hose
22. Fuel tank

<FUEL FILLER NECK>

27

24
25

26

1
23

AC300410AC

Fuel filler neck removal steps Fuel filler neck removal steps
1. Fuel filler hose connection <Fuel 24. Fuel tank cap
filler neck side> 25. Fuel filler neck
2. Fuel filler neck breather hose 26. Fuel filler neck valve
connection <Fuel filler neck side> 27. Gasket
23. Fuel filler neck protector
 FUEL SUPPLY
FUEL TANK
13C-13

REMOVAL SERVICE POINTS CAUTION

<<A>> REAR DIFFERENTIAL SUPPORT Support the fuel tank assembly securely so that
MEMBER INSTALLATION NUTS AND it does not fall off from the transmission jack.
BOLTS/FUEL TANK ASSEMBLY REMOVAL 3. Tilt the fuel tank assembly to disconnect the
Rear differential connectors.
Fuel tank assembly
carrier assembly
Towards front Rear differential
of vehicle carrier assembly

Tilt
Towards front
of vehicle AC300033AB
Lower
Fuel tank assembly
1. Remove the rear differential support member AC300043AB

installation nuts and bolts, and then tilt the rear 4. Remove the fuel tank assembly to the direction
differential carrier assembly (Refer to GROUP shown, being careful not to strike it against the
27B − Rear Differential Carrier Assembly rear differential carrier assembly.
P.27B-16).
<<B>> FUEL TANK GAUGE UNIT/FUEL TANK
PUMP AND GAUGE ASSEMBLY REMOVAL
CAUTION
When withdrawing the fuel tank gauge unit, fuel
tank pump and gauge assembly from the fuel
tank, be careful not damage the module unit and
the float.

Fuel tank assembly INSTALLATION SERVICE POINS

Transaxle jack AC107196 AD >>A<< FUEL PUMP SUCTION TUBE <4WD>/FUEL
HIGH-PRESSURE HOSE INSTALLATION
2. Raise and support the fuel tank assembly with a
transmission jack, and remove the mounting nuts CAUTION
and bolts.
Towards front
of vehicle Rear differential Corresponding side
Fuel tank assembly carrier assembly
Fuel high-pressure hose or
fuel pump suction tube

3 mm
Quick connector
AC300047AE
Tilt
AC300040AB After connecting the fuel high-pressure hose or
fuel pump suction tube, slightly pull it to ensure
that it is installed securely. Also confirm that
there is a play approximately 3 mm.
13C-14 FUEL SUPPLY
FUEL TANK

FUEL PUMP ASSEMBLY DISASSEMBLY

AND REASSEMBLY <2WD>
M1135004600380

3
2
10
1N
N5 8
6
N5 4
9
11 7

AC309295 AB

Disassembly steps Disassembly steps (Continued)

1. Gasket >>A<< 10. Fuel tank grommet
2. Fuel tank pump connector 11. Fuel tank filter assembly
connection
3. Fuel pump bracket REASSEMBLY SERVICE POINT
4. Fuel pump hose >>A<< FUEL TANK GROMMET/O-RING
>>A<< 5. O-ring INSTALLATION
6. Fuel pump tube
Apply gasoline on the grommet and the O-ring before
7. Fuel pump bracket
8. Fuel tank pump
mounting them to prevent damage or twisting.
9. Fuel tank pump cushion
 FUEL SUPPLY
FUEL TANK
13C-15
FUEL TANK PUMP AND GAUGE
ASSEMBLY DISASSEMBLY AND
REASSEMBLY <4WD>
M1135004600391

<4G63> <4G69>

5 5
4
14 4
2 1N 2 1N 14
3 N 10
12 3 N 10
8 9 6
N 10
12
6 N 10
7 13
13
11
15 15 11

AC309123 AC309123
AC309296 AB

Disassembly steps Disassembly steps (Continued)

1. Gasket 11. Fuel pump bracket
2. Fuel tank gauge unit connector 12. Fuel tank pump
connection 13. Fuel tank pump cushion
3. Fuel tank gauge unit >>A<< 14. Fuel tank grommet
4. Fuel tank pump connector 15. Fuel tank filter assembly
connection
5. Fuel pump bracket REASSEMBLY SERVICE POINT
6. Fuel pump hose >>A<< FUEL TANK GROMMET/O-RING
7. Fuel tank assist pump <4G63> INSTALLATION
8. Fuel pump tube <4G63>
Apply gasoline on the grommet and the O-ring before
9. Fuel pump pressure regulator
<4G69>
mounting them to prevent damage or twisting.
>>A<< 10. O-ring
13C-16 FUEL SUPPLY
FUEL TANK

FUEL TANK GAUGE UNIT DISASSEMBLY AND REASSEMBLY

M1135051100068

<2WD> <4WD>

3
3

1
1
2

AC102461 AD

Disassembly steps Disassembly steps (Continued)

1. Gasket 2. Fuel in tank filter <4WD>
3. Fuel tank gauge unit