ENGINE
CONTENTS
VQ
SERVICE INFORMATION ............................ 2
PREPARATION ................................................... 2
Special Service Tool ................................................. 2
FUEL SYSTEM .................................................... 3
Checking Fuel Line ................................................... 3
General Precaution ................................................... 3
FUEL TANK ......................................................... 5
Component ................................................................ 5
Removal and Installation ........................................... 5
FUEL LEVEL SENSOR UNIT, FUEL FILTER
AND FUEL PUMP ASSEMBLY .........................10
Component .............................................................. 10
Removal and Installation ......................................... 10
SERVICE DATA AND SPECIFICATIONS
(SDS) ..................................................................12
Standard and Limit .................................................. 12
YD
SERVICE INFORMATION ........................... 13
APPLICATION NOTICE .....................................13
How to Check Fuel Filter Type ................................ 13
PREPARATION ..................................................14
Commercial Service Tool ........................................ 14
FL-1
SECTION
FUEL SYSTEM
FL FL
E
FUEL SYSTEM .................................................. 15 F
Checking Fuel Line ..................................................15
General Precaution ..................................................15
G
FUEL FILTER .................................................... 16
Component (Type1) .................................................16
Removal and Installation (Type 1) ...........................16
Sedimentor Switch (Type 1) ....................................18 H
Air Bleeding (Type 1) ...............................................18
Draining Water from Fuel Filter (Type 1) .................19
Draining Water from Sedimentor (Type 1) ...............19 I
Component (Type 2) ................................................20
Removal and Installation (Type 2) ...........................21
Air Bleeding (Type 2) ...............................................21 J
Draining Water from Fuel Filter (Type 2) .................22
Fuel Filter Sensor (With Fuel Filter Warning)
(Type 2) ...................................................................22
K
FUEL COOLER ................................................. 23
Component (4WD Models Only) ..............................23
Removal and Installation (4WD Models Only) .........23 L
FUEL TANK ...................................................... 25
Component ..............................................................25
Removal and Installation .........................................25 M
FUEL LEVEL SENSOR UNIT ........................... 30
Component ..............................................................30
N
Removal and Installation .........................................30
SERVICE DATA AND SPECIFICATIONS
O
(SDS) ................................................................. 32
Standard and Limit ..................................................32
 PREPARATION
< SERVICE INFORMATION > [VQ]

SERVICE INFORMATION
PREPARATION
Special Service Tool INFOID:0000000001620131

Tool name Description

Fuel tank lock ring wrench Removing and installing fuel tank lock ring

ZZA0122D

FL-2
 FUEL SYSTEM
< SERVICE INFORMATION > [VQ]
FUEL SYSTEM
A
Checking Fuel Line INFOID:0000000001620132

Inspect fuel lines, fuel filler cap and fuel tank for improper attach- FL
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
C

SMA803A E
General Precaution INFOID:0000000001620133

WARNING: F
When replacing fuel line parts, be sure to observe the following.
• Put a “CAUTION: INFLAMMABLE” sign in the workshop.
• Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher. G
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
• Use gasoline required by the regulations for octane number. Refer to GI-4, "Precaution for Fuel".
• Before removing fuel line parts, perform the following procedures: H
- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
- Release fuel pressure from the fuel lines. Refer to EC-74, "Fuel Pressure Check" (models for Austra- I
lia) or EC-558, "Fuel Pressure Check" (models except for Australia).
- Disconnect the battery cable from the negative terminal.
• Always replace O-rings and clamps with new ones.
• Do not kink or twist hoses when they are being installed. J
• Do not tighten hose clamps excessively to avoid damaging hoses.
Tighten high-pressure rubber hose clamp so that clamp end
is 3 mm (0.12 in) from hose end. K
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
L

MMA104A

FL-3
 FUEL SYSTEM
< SERVICE INFORMATION > [VQ]
• After connecting the fuel tube quick connectors, make sure
the quick connectors are secure.
Ensure that the connector and resin tube do not contact any
adjacent parts.
• After installing tubes, make sure there is no fuel leakage at
connections in the following steps.
- Apply fuel pressure to fuel lines with turning ignition switch
ON (with engine stopped). Then check for fuel leaks at con-
nections.
- Start the engine and rev it up and check for fuel leaks at con-
nections.
• Use only a Genuine NISSAN fuel filler cap as a replacement. If
an incorrect fuel filler cap is used, the MIL may come on.
• For servicing “Evaporative Emission System” parts, refer to
EC-41 (models for Australia) or EC-537 (models except for
Australia).

PBIC1268E

FL-4
 FUEL TANK
< SERVICE INFORMATION > [VQ]
FUEL TANK
A
Component INFOID:0000000001620134

FL

J
PBIC4219E

1. Fuel filler cap 2. Grommet 3. Fuel filler tube K

4. EVAP tube 5. Fuel tank 6. Fuel tank band
7. Fuel tank band 8. Fuel feed tube 9. Vent hose
10. Fuel filler hose L
A. To engine

Removal and Installation INFOID:0000000001620135 M

REMOVAL
WARNING: N
Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "General Precau-
tion".
• Drain fuel from fuel tank if necessary. O
• Perform work on level place.
1. Open fuel filler lid.
2. Open the fuel filler cap and release the pressure inside fuel tank. P

FL-5
 FUEL TANK
< SERVICE INFORMATION > [VQ]
3. Check fuel level on level place. If fuel gauge indicates more than
the level shown in figure (full or almost full), drain fuel from fuel
tank until gauge indicates level as shown in the figure or below.
NOTE:
Because fuel will be spilled when removing fuel level sensor
unit, fuel filter and fuel pump assembly for the top of the fuel is
above the fuel level sensor unit, fuel filter and fuel pump assem-
bly installation surface.
• As a guide, fuel level becomes the position as shown in the
figure or below when approximately 20 (4-3/8 lmp gal) of
fuel are drained from fuel tank. PBIC3631E
• In a case that fuel pump does not operate, perform the follow-
ing steps.
a. Insert hose of less than 15 mm (0.59 in) in diameter into fuel filler tube through fuel filler opening to draw
fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube.
c. Insert tube into fuel tank to draw fuel from fuel tank.
• As a guide, fuel level becomes the position shown in figure or below when approximately 20 liter (17-5/8
lmp qt) of fuel are drained from full tank.
NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit is removed.
4. Release the fuel pressure from fuel lines. Refer to EC-74, "Fuel Pressure Check" (models for Australia) or
EC-558, "Fuel Pressure Check" (models except for Australia).
5. Disconnect the battery cable from the negative terminal.
6. Disconnect fuel feed tube (C).

A : Harness connector
B : EVAP tube
D : Fuel filler hose
E : Vent hose

PBIC3841E

• Disconnect quick connector of fuel feed tube as follows.

NOTE:
• Hold the sides of the connector, push in tubs and pull out the
tube.
• If the connector and the tube are stuck together, push and pull
several times until they start to move. Then disconnect them by
pulling.

SFE562A

CAUTION:

FL-6
 FUEL TANK
< SERVICE INFORMATION > [VQ]
• Quick connector can be disconnected when the tabs are
completely depressed. Do not twist it more than necessary. A
• Do not use any tools to disconnect quick connector.
• Keep resin tube away from heat. Be especially careful when
welding near the resin tube.
FL
• Prevent acid liquid such as battery electrolyte etc. from get-
ting on resin tube.
• Do not bend or twist resin tube during installation and
removal. C
• Do not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is replaced.
• When resin tube or fuel level sensor unit is replaced, also D
replace retainer with a new one. Replace same color retainer
as before replacing.

Retainer color : Green E

G
SBIA0504E

• To keep clean the connecting portion and to avoid damage

and foreign materials, cover them completely with plastic H
bags or something similar.

PBIC0163E
K

7. Using a transmission jack (A), support the bottom of fuel tank

(1). L
CAUTION:
Support the position that fuel tank bands do not engage.
M

PBIC3377E
O

FL-7
 FUEL TANK
< SERVICE INFORMATION > [VQ]
8. Remove fuel tank bands, and lower the transmission jack care-
fully until harness connector (A), EVAP tube (B), fuel filler hose
(D) and vent hose (E) can be disconnected.
9. Disconnect harness connector (A), EVAP tube (B), fuel filler
hose (D) and vent hose (E).

C : Fuel feed tube

PBIC3841E

10. Supporting with hands, lower transmission jack carefully, and remove fuel tank.
CAUTION:
• Pay attention not to fall fuel tank.
• Make sure that all connection points have been disconnected.
• Confirm there is no interference with vehicle.
11. Remove fuel filler tubes, fuel filler hoses and vent hoses if necessary.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Surely clamp fuel hoses and insert hose to the length below.

Fuel filler hose : 35 mm (1.38 in)

The other hose : 25 mm (0.98 in)
• Be sure hose clamp is not positioned on swelled area of fuel tube.
• Position fuel filler hose clamp (2) between paint marking (B).

1 : Fuel filler hose

3 : Fuel filler tube
A : paint marking

PBIC4163E

• Position vent hose clamp (2) as shown in the figure.

1 : Vent hose
3 : Vent tube (part of fuel filler tube)

PBIC4162E

FL-8
 FUEL TANK
< SERVICE INFORMATION > [VQ]
• Tighten fuel hose clamp so that the flange (A) of bolt head is on the
paint mark (B) on the band. A

FL

PBIC4058E

D
• Fit mounting band pin to the vehicle side securely.
• Before fixing the fuel tank, temporarily install the fuel filler tube.
CAUTION: E
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the specified
torque.
• Connect quick connector as follows.
F
1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below. G
• Visually confirm that the two tabs are connected to connector.
• Pull the tube and connector to make sure they are securely
connected.
H

PBIC1653E

K
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
1. Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pres- L
sure to fuel piping.
2. Start engine and rev it up and make sure there is no fuel leakage at connections.
M

FL-9
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< SERVICE INFORMATION > [VQ]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Component INFOID:0000000001620136

PBIC3842E

1. Lock ring 2. Fuel level sensor unit, fuel filter and 3. Seal packing
fuel pump assembly
4. Fuel tank
A. Refer to FL-10.

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000001620137

REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "General Precau-
tion".
1. Remove fuel tank from the vehicle. Refer to FL-5.
2. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.

PBIC0240E

3. Remove fuel level sensor unit, fuel filter and fuel pump assembly.
CAUTION:
• Do not bend the float arm during removal.
• Avoid impacts such as falling when handling components.
INSPECTION AFTER REMOVAL
Make sure fuel level sensor unit, fuel filter and fuel pump assembly is free from foreign materials. If any are
found, remove them.
INSTALLATION

FL-10
 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
< SERVICE INFORMATION > [VQ]
Note the following, and install in the reverse order of removal.
• Install fuel level sensor unit, fuel filter and fuel pump assembly (1) A
with aligning mating marks (A) on fuel tank and fuel level sensor
unit, fuel filter and fuel pump assembly as shown in the figure.
FL
: Vehicle front

PBIC3843E D

• Install lock ring (1), and tighten lock ring by hand. Then tighten lock
ring with a fuel tank lock ring wrench (commercial service tool), E
aligning mating marks (A) on fuel tank and lock ring as shown in
the figure.

: Vehicle front F

PBIC3844E

INSPECTION AFTER INSTALLATION H

Make sure there is no fuel leakage at connections in the following steps.
• Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pressure
to fuel piping. I
• Start engine and rev it up and make sure there is no fuel leakage at the fuel system connections.

FL-11
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [VQ]
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit INFOID:0000000001620138

Fuel tank capacity Approx. 80 (17-5/8 Imp gal)

Fuel recommendation Refer to GI-4.

FL-12
 APPLICATION NOTICE
< SERVICE INFORMATION > [YD]

SERVICE INFORMATION A
APPLICATION NOTICE
How to Check Fuel Filter Type INFOID:0000000001620139
FL
• There are two kinds of fuel filter, refer to the figure about a difference of type 1 and type 2.
- Type 1
C

1. Fuel filter
2. Mounting nut D
3. Priming pump
: Vehicle front
E

PBIC4888E
F

-
Type 2 G

1. Fuel filter
2. Mounting nut H
3. Mounting bolt
4. Priming pump
: Vehicle front I

PBIC4861E

FL-13
 PREPARATION
< SERVICE INFORMATION > [YD]
PREPARATION
Commercial Service Tool INFOID:0000000001620140

Tool name Description

Fuel filter wrench Removing fuel filter

PBIC0519E

Fuel tank lock ring wrench Removing and installing fuel tank lock ring

ZZA0122D

FL-14
 FUEL SYSTEM
< SERVICE INFORMATION > [YD]
FUEL SYSTEM
A
Checking Fuel Line INFOID:0000000001620141

Inspect fuel lines, fuel filler cap and fuel tank for improper attach- FL
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
C

SMA803A E
General Precaution INFOID:0000000001620142

WARNING: F
When replacing fuel line parts, be sure to observe the following.
• Put a “CAUTION: INFLAMMABLE” sign in workshop.
• Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher. G
• Do not smoke while servicing fuel system. Keep open flames and spark away from work area.
CAUTION:
• Use diesel fuel required by the regulations for cetane number. Refer to GI-4, "Precaution for Fuel".
• Before removing fuel line parts, perform the following procedures: H
- Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
- Disconnect the battery cable from the negative terminal. I
• Always replace O-ring and clamps with new ones.
• Do not kink or twist tubes when they are being installed.
• Do not tighten hose clamps excessively to avoid damaging hoses.
• After connecting fuel tube quick connectors, make sure quick J
connectors are secure.
Ensure that connector and resin tube do not contact any adja-
cent parts. K
• After installing tubes, make sure there is no fuel leakage at
connections in the following steps.
- Start the engine and rev it up and check for fuel leaks at con-
L
nections.

SBIA0504E

FL-15
 FUEL FILTER
< SERVICE INFORMATION > [YD]
FUEL FILTER
Component (Type1) INFOID:0000000001620143

1. VIN<VSK***D40***XXXX

PBIC3369E

1. Fuel filter bracket 2. Fuel filter 3. O–ring

4. Drain plug
A. Refer to FL-16

2. VIN>VSK***D40***XXXX

E1BIA0195GB

1. Fuel filter bracket 2. Fuel filter 3. O–ring

4. Drain plug
A. Refer to FL-16

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation (Type 1) INFOID:0000000001620144

REMOVAL

FL-16
 FUEL FILTER
< SERVICE INFORMATION > [YD]
1. Disconnect fuel hoses at fuel filter.
A
1 : Fuel filter
2 : Fuel hose (feed)
3 : Fuel hose (return) FL
CAUTION:
Plug the pipe to prevent fuel from draining.
C

PBIC3370E

D
2. Loosen mounting nuts (2) and remove fuel filter (1).

: Vehicle front E
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off. F

G
PBIC3337E

3. Using band-type fuel filter wrench (A) (commercial service tool),

H
remove fuel filter (1).
4. Turn fuel filter (1) upside down to drain fuel.
5. Remove drain plug (2) from fuel filter. I

PBIC3371E
K
INSTALLATION
Note the following, and install in the reverse order of removal.
• Replace O-ring on drain plug with new one. L
• Screw the fuel filter by hand until packing contacts sealing surface of fuel filter bracket. Then tighten it by
turning approximately 2/3 turn.
M
Fuel filter (Torque value) VIN<VSK***D40***XXXX
: 13.5 N·m (1.4 kg-m, 10 ft-lb)
N
Fuel filter (Torque value) VIN>VSK***D40***XXXX
: 21.5 N·m (2.2 kg-m, 16 ft-lb) O

FL-17
 FUEL FILTER
< SERVICE INFORMATION > [YD]
• Install fuel filter (1), and tighten mounting nuts (2) to the specified
torque.

: Vehicle front

Fuel filter mounting nuts

: 13.5 N·m (1.4 kg-m, 10 ft-lb)

PBIC3337E

• After installation, bleed air from fuel line. Refer to FL-18, "Air Bleeding (Type 1)".
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
• Start the engine and rev it up and make sure there is no fuel leakage at connections.
Sedimentor Switch (Type 1) INFOID:0000000001620145

REMOVAL
1. Remove sedimentor.
2. Remove sedimentor switch from sedimentor.
INSPECTION AFTER REMOVAL
• Check continuity between harness connector (A) No. 1 and No. 2
when float (B) is lifted and when not lifted.

C : Lift up

Standard:
Lifted : Continuity should exist.
Not lifted : Continuity should not exist.
• If out of standard, replace sedimentor switch (1).
PBIC4060E

INSTALLATION
Following instructions below, install in reverse order of removal.
• Replace O-ring on sedimentor switch with new one.

: 4.9 N·m (0.5 kg-m, 43 in-lb)

• Tighten sedimentor mounting bolts to the specified torque.

Sedimentor mounting bolts

: 11.0 N·m (1.1 kg-m, 8 ft-lb)

Air Bleeding (Type 1) INFOID:0000000001620146

After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as
follows:

FL-18
 FUEL FILTER
< SERVICE INFORMATION > [YD]
• Move priming pump (1) up and down to bleed air from fuel path.
When air is bled, pumping of priming pump becomes heavy stop A
operation at that time.

FL

PBIC3372E

D
• Crank engine until it starts. Do not crank engine for more than 30 seconds.
• If engine does not start, stop cranking and repeat step 1 above.
• If engine does not operate smoothly after it has started, race it two or three times. E
• If air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of hose
between fuel filter and electronically controlled fuel pump. After that, operate priming pump and confirm that
fuel comes out.
CAUTION: F
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.
G
Draining Water from Fuel Filter (Type 1) INFOID:0000000001620147

1. Prepare a tray (A) under the drain plug (1).

H
2. Loosen drain plug (1), and operate priming pump (2) to drain
water from fuel filter.
CAUTION:
• Water in filter is drained with fuel. Prepare larger capacity I
pan than fuel filter volume.
• Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator. J
3. Replace O-ring on drain plug with new one.
4. After draining, close drain plug to specified torque.
PBIC3373E
K
Drain plug VIN<VSK***D40***XXXX
: 1.3 N·m (0.13 kg-m, 12 in-lb)
L

Drain plug VIN<VSK***D40***XXXX

: 1.75 N·m (0.18 kg-m, 15 in-lb) M
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak.
N
5. Bleed air in fuel piping. Refer to FL-18, "Air Bleeding (Type 1)".
6. Start engine and make sure there is no fuel leakage.
Draining Water from Sedimentor (Type 1) INFOID:0000000001620148 O

CAUTION:
P

FL-19
 FUEL FILTER
< SERVICE INFORMATION > [YD]
• Drain water from sedimentor when fuel filter warning lamp
turns on as follows:

PBIC2664E

1. Prepare a tray under the drain plug.

2. Loosen air bleeder screw of the sedimentor.
3. Loosen drain cock and drain water.
CAUTION:
• Loosening drain cock four to five turns causes water to
start draining. Do not remove drain cock by loosening it
excessively.
• Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
• Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator. SMA281C

4. After draining, close drain cock by hand.

CAUTION:
If drain cock is tightened excessively, it may be damaged and fuel will leak. Do not use tools to
tighten drain cock.
5. Bleed air in fuel piping. Refer to FL-18, "Air Bleeding (Type 1)".
6. Start engine and make sure there is no fuel leakage.
Component (Type 2) INFOID:0000000001620149

MBIB1590E

FL-20
 FUEL FILTER
< SERVICE INFORMATION > [YD]

1. Bracket 2. Bracket 3. Fuel filter assembly A

4. Fuel hose 5. Priming pump
A. To fuel tube B. To centralized under-floor piping

• Refer to GI-9, "Component" for symbol marks in the figure. FL

Removal and Installation (Type 2) INFOID:0000000001620150

C
REMOVAL
1. Disconnect fuel hoses.
CAUTION: D
Plug the pipe to prevent fuel from draining.
2. Remove fuel filter assembly from bracket.
CAUTION: E
Do not splash fuel during removal. If fuel is splashed, immediately wipe it off.
INSTALLATION
Note the following, and install in the reverse order of removal. F
• Install fuel filter (1), and tighten mounting nuts (2) to the specified
torque.

3. Mounting bolt G
4. Priming pump
: Vehicle front
H

Fuel filter mounting nuts

: 13.5 N·m (1.4 kg-m, 10 ft-lb) I
PBIC4861E

• When assembling fuel filter assembly and bracket, adjust the angle J
of fuel filter assembly as shown in the figure.
• After installation, bleed air from fuel line. Refer to FL-21, "Air
Bleeding (Type 2)".
K

MBIB1591E
M
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
• Start the engine and rev it up and make sure there is no fuel leakage at connections. N
Air Bleeding (Type 2) INFOID:0000000001620151

After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as O
follows:

FL-21
 FUEL FILTER
< SERVICE INFORMATION > [YD]
1. Prime the circuit using the priming pump (1).
2. Perform engine cranking with repeating several times until
engine starting.
NOTE:
• If engine does not start, stop cranking and repeat step “1”
above.
• If engine does not operate smoothly after it has started, race it
two or three times.
CAUTION:
Crank engine until it starts. Do not crank engine for more
than 30 seconds. PBIC4860E

Draining Water from Fuel Filter (Type 2) INFOID:0000000001620152

1. Connect drain hose (suitable hose) to the end of drain plug (A).
2. Prepare a tray at the drain plug open end.
3. Loosen drain plug, and operate priming pump to drain water
from fuel filter.
CAUTION:
• Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
• Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
4. After draining, close drain plug by hand.
CAUTION: MBIB1593E

If drain plug is tightened excessively, it may be damaged

and fuel will leak. Do not use tools to tighten drain plug.
5. Bleed air in fuel piping. Refer to FL-21, "Air Bleeding (Type 2)".
6. Start engine and make sure there is no fuel leakage.
Fuel Filter Sensor (With Fuel Filter Warning) (Type 2) INFOID:0000000001620153

• Drain water from fuel filter, when the fuel filter warning lamp turns
ON.

PBIC2664E

NOTE:
If the fuel filter warning lamp turns ON, after draining water from fuel filter. Perform the following.
• Disconnect fuel filter sensor connector.
• Check condition of the fuel filter warning lamp.
- If the warning lamp turns ON, check the harness between combination meter and fuel filter sensor. Refer to
DI-31, "Wiring Diagram - WARN -".
- If the warning lamp turns OFF, replace the fuel filter sensor and fuel filter assembly.

FL-22
 FUEL COOLER
< SERVICE INFORMATION > [YD]
FUEL COOLER
A
Component (4WD Models Only) INFOID:0000000001620154

FL

I
PBIC4059E

1. Fuel tube (return) (to fuel tank) 2. Fuel tube (return) (to engine) 3. Bracket J
4. Protector (fuel cooler) 5. Protector (fuel tube) 6. Fuel cooler assembly
7. Bracket
K
Removal and Installation (4WD Models Only) INFOID:0000000001620155

REMOVAL L
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-15, "General Precau-
tion".
M
1. Remove protector (fuel tube).
2. Remove protector (fuel cooler) mounting bolts (3 pieces) then disconnect fuel tubes from fuel cooler
assembly.
N
CAUTION:
• Plug fuel tubes and fuel cooler assembly to prevent fuel from draining.
• Do not splash fuel during removal. If fuel is splashed, immediately wipe it off.
3. Remove fuel cooler assembly from protector (fuel cooler) O
CAUTION:
• Do not bend fuel tubes during removal.
• Avoid impacts such as falling when handling components. P
INSTALLATION
Note the following, and install in the reverse order of removal.
• Insert hose to the length below when there is no spool on the fuel tube and surely clamp fuel hoses.

Fuel hose : 25 mm (0.98 in)

• Be sure hose clamp is not positioned on swelled area of fuel tube.

FL-23
 FUEL COOLER
< SERVICE INFORMATION > [YD]
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
• Start engine and rev it up and make sure there is no fuel leakage at connections.

FL-24
 FUEL TANK
< SERVICE INFORMATION > [YD]
FUEL TANK
A
Component INFOID:0000000001620156

FL

J
PBIC5000E

1. Fuel filler cap 2. Grommet 3. Fuel filler tube K

4. EVAP tube 5. Fuel tank 6. Fuel tank band
7. Fuel tank band 8. Fuel feed tube 9. Vent hose
10. Fuel filler hose 11. Fuel return tube L
A. To fuel filter B. To fuel cooler (under floor)

Removal and Installation INFOID:0000000001620157 M

REMOVAL
WARNING: N
Be sure to read “General Precautions” when working on fuel system. Refer to FL-15, "General Precau-
tion".
1. Open fuel filler lid. O
2. Open the fuel filler cap and release the pressure inside fuel tank.

FL-25
 FUEL TANK
< SERVICE INFORMATION > [YD]
3. Check fuel level on level place. If fuel gauge indicates more than
the level shown in figure (full or almost full), drain fuel from fuel
tank until gauge indicates level as shown in the figure or below.
NOTE:
Because fuel will be spilled when removing fuel level sensor unit
for the top of the fuel is above fuel level sensor unit installation
surface.
• As a guide, fuel level becomes the position as shown in the
figure or below when approximately 20 (4-3/8 lmp gal) of
fuel are drained from fuel tank.
• Refer to the following for draining fuel. PBIC3631E
a. Insert fuel tube of less than 15 mm (0.59 in) in diameter into fuel
filler tube through fuel filler opening to draw fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube.
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
4. Disconnect the battery cable from the negative terminal.
5. Disconnect fuel feed tube (C) and fuel return tube (D).

A : Harness connector
B : EVAP tube
E : Fuel filler hose
F : Vent hose

PBIC3375E

Disconnect quick connector of fuel feed tube and fuel return tube as
follows.
NOTE:
• Hold the sides of the connector, push in tubs and pull out the tube.
• If the connector and the tube are stuck together, push and pull sev-
eral times until they start to move. Then disconnect them by pull-
ing.

SFE562A

CAUTION:

FL-26
 FUEL TANK
< SERVICE INFORMATION > [YD]
• Quick connector can be disconnected when the tabs are com-
pletely depressed. Do not twist it more than necessary. A
• Do not use any tools to disconnect quick connector.
• Keep resin tube away from heat. Be especially careful when
welding near the resin tube.
FL
• Prevent acid liquid such as battery electrolyte etc. from get-
ting on resin tube.
• Do not bend or twist resin tube during installation and
removal. C
• Do not remove the remaining retainer on hard tube (or equiv-
alent) except when resin tube or retainer is replaced.
• When resin tube or fuel level sensor unit is replaced, also D
replace retainer with a new one. Replace same color retainer
as before replacing.

Retainer color : Green (Fuel feed tube) E

: Gray (Fuel return tube)

G
SBIA0504E

• To keep clean the connecting portion and to avoid damage

and foreign materials, cover them completely with plastic H
bags or something similar.

PBIC0163E
K

6. Using a transmission jack (A), support the bottom of fuel tank

(1).
L
CAUTION:
Support the position that fuel tank bands do not engage.

PBIC3377E

7. Remove fuel tank bands, and lower the transmission jack care- O
fully until harness connector (A), EVAP tube (B), fuel filler hose
(E) and vent hose (F) can be disconnected.
P
C : Fuel feed tube
D : Fuel return tube
8. Disconnect harness connector (A), EVAP tube (B), fuel filler
hose (E) and vent hose (F).

PBIC3375E

FL-27
 FUEL TANK
< SERVICE INFORMATION > [YD]
9. Supporting with hands, lower transmission jack carefully, and remove fuel tank.
CAUTION:
• Pay attention not to fall fuel tank.
• Make sure that all connection points have been disconnected.
• Confirm there is no interference with vehicle.
10. Remove fuel filler tubes, fuel filler hoses and vent hoses if necessary.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Surely clamp fuel hoses and insert hose to the length below.

Fuel filler hose : 35 mm (1.38 in)

The other hose : 25 mm (0.98 in)
• Be sure hose clamp is not positioned on swelled area of fuel tube.
• Position fuel filler hose clamp (2) between paint marking (B).

1 : Fuel filler hose

3 : Fuel filler tube
A : paint marking

PBIC4163E

• Position vent hose clamp (2) as shown in the figure.

1 : Vent hose
3 : Vent tube (part of fuel filler tube)

PBIC4162E
• Tighten fuel hose clamp so that the flange (A) of bolt head is on the
paint mark (B) on the band.

PBIC4058E

• Fit mounting band pin to the vehicle side securely.

• Before fixing the fuel tank, temporarily install the fuel filler tube.
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the specified
torque.
• Connect quick connector as follows.
1. Check connection for damage and foreign materials.
2. Align the connector with the tube, then insert connector straight into tube until a click is heard.

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 FUEL TANK
< SERVICE INFORMATION > [YD]
3. After connecting, make sure that the connection is secure by following the steps below.
• Visually confirm that the two tabs are connected to connector. A
• Pull the tube and connector to make sure they are securely
connected.
FL

D
PBIC1653E

INSPECTION AFTER INSTALLATION E

Make sure there is no fuel leakage at connections in the following step.
• Start engine and rev it up and make sure there is no fuel leakage at connections.
F

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 FUEL LEVEL SENSOR UNIT
< SERVICE INFORMATION > [YD]
FUEL LEVEL SENSOR UNIT
Component INFOID:0000000001620158

PBIC3374E

1. Lock ring 2. Fuel level sensor unit 3. Seal packing

4. Fuel tank
A. Refer to FL-30.

• Refer to GI-9, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000001620159

REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-15, "General Precau-
tion".
1. Remove fuel tank from the vehicle. Refer to FL-25.
2. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.

PBIC0240E

3. Remove fuel level sensor unit.

CAUTION:
• Do not bend the float arm during removal.
• Avoid impacts such as falling when handling components.
INSPECTION AFTER REMOVAL
Make sure fuel level sensor unit is free from foreign materials. If any are found, remove them.
INSTALLATION
Note the following, and install in the reverse order of removal.

FL-30
 FUEL LEVEL SENSOR UNIT
< SERVICE INFORMATION > [YD]
• Install fuel level sensor unit (1) with aligning mating marks (A) on
fuel tank and fuel level sensor unit as shown in the figure. A

: Vehicle front
FL

PBIC3506E

D
• Install lock ring (1), and tighten lock ring by hand. Then tighten lock
ring with a fuel tank lock ring wrench (commercial service tool),
aligning mating marks (A) on fuel tank and lock ring as shown in E
the figure.

: Vehicle front
F

G
PBIC3632E

INSPECTION AFTER INSTALLATION

H
Make sure there is no fuel leakage at connections in the following steps.
• Start engine and rev it up and make sure there is no fuel leakage at connections.

FL-31
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit INFOID:0000000001620160

Fuel tank capacity Approx. 80 (17-5/8 Imp gal)

Fuel recommendation Refer to GI-4.

FL-32