Align the fuel tank side mark with the hose side mark.

Install the fuel tank to filler pipe hose to the fuel tank.

Install the No. 3 fuel tank protector and attach the 4 clamps.

Install the 2 bolts.

• Момент затяжки:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank.

Align the protrusion of the fuel tank vent tube with the groove of the fuel tank.

• ПРИМЕЧАНИЕ:

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

Install the fuel tank vent tube to the fuel tank.

Put a new retainer on the fuel tank. While holding the fuel tank vent tube, tighten the retainer one complete turn by hand.

• УКАЗАНИЕ:

• Make sure the start marks on the retainer and fuel tank are aligned, and then tighten the retainer.

Set SST on the retainer.

• SST
• 09808-14030

• УКАЗАНИЕ:

Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank as shown in the illustration.

• SST
• 09808-14030

• УКАЗАНИЕ:

• Fit the tips of SST onto the ribs of the retainer.

Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.

• ПРИМЕЧАНИЕ:

Check that there are no scratches or foreign objects on the connecting parts.

Check that the fuel tube joints are inserted securely.

Check that the fuel tube joint clips are on the collars of the fuel tube joints.

After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.

Text in Illustration

*1	Fuel Tube Joint
*2	O-Ring
*3	Fuel Tube
*4	Fuel Tube Joint Clip
*a	CORRECT
*b	INCORRECT

Install the fuel tank main tube and fuel return tube to the fuel tank.

Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.

• ПРИМЕЧАНИЕ:

Check that there are no scratches or foreign objects on the connecting parts.

Check that the fuel tube joints are inserted securely.

Check that the fuel tube joint clips are on the collars of the fuel tube joints.

After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.

Text in Illustration

*1	Fuel Tube Joint
*2	O-Ring
*3	Fuel Tube
*4	Fuel Tube Joint Clip
*a	CORRECT
*b	INCORRECT

Install the fuel tank main tube to the fuel tank.

Install the fuel return tube to the fuel tank and attach the clamp.

Install 3 new fuel tank cushions to the fuel tank.

Set the fuel tank on a transmission jack and rise the transmission jack.

• ПРИМЕЧАНИЕ:

• Do not allow the fuel tank to contact the vehicle, especially the differential.

Install the 2 fuel tank bands with the 2 pins and 2 clips.

Connect the 2 fuel tank bands with the 2 bolts.

• Момент затяжки:
• 40 N*m{ 408 kgf*cm, 30 ft.*lbf}

Connect the fuel tank to filler pipe hose to the filler pipe.

Connect the fuel tank breather tube (See page ).

Connect the fuel tank breather tube (See page ).

Connect the fuel return tube (See page ).

Connect the fuel cut off tube (See page ).

Install the No. 1 fuel tank protector with the 6 bolts.

• Момент затяжки:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Connect the fuel sender gauge connector.

Install the rear floor service hole cover with the 3 screws.

for 60/40 Split Double-folding Seat Type LH Side:

Install the rear seat assembly LH (See page ).

for 60/40 Split Slide Walk-in Seat Type LH Side:

Install the rear seat assembly LH (See page ).

Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

• УКАЗАНИЕ:

• When checking for fuel leaks, make sure that there is pressure in the fuel line.

for 60/40 Split Double-folding Seat Type LH Side:

Remove the rear seat assembly LH (See page ).

for 60/40 Split Slide Walk-in Seat Type LH Side:

Remove the rear seat assembly LH (See page ).

Remove the 3 screws and rear floor service hole cover.

Disconnect the fuel sender gauge connector.

Remove the 6 bolts and No. 1 fuel tank protector.

Disconnect the fuel tank breather tube (See page ).

Disconnect the fuel cut off tube (See page ).

Disconnect the fuel return tube (See page ).

Disconnect the fuel tank breather tube (See page ).

Disconnect the fuel tank to filler pipe hose from the filler pipe.

Place a transmission jack under the fuel tank.

Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.

Slowly lower the transmission jack slightly.

Remove the No. 1, No. 2 and No. 3 fuel tank cushions from the fuel tank.

Remove the 2 fuel tube joint clips and pull out the fuel tank main tube and fuel return tube.

• ПРИМЕЧАНИЕ:

Remove the fuel tank main tube and fuel return tube from the fuel tank.

Remove the 2 fuel tube joint clips and pull out the fuel tank main tube and fuel return tube.

• ПРИМЕЧАНИЕ:

Detach the clamp and remove the fuel return tube.

Remove the fuel tank main tube from the fuel tank.

Set SST on the retainer.

• SST
• 09808-14030

• УКАЗАНИЕ:

Using SST, loosen the retainer.

• SST
• 09808-14030

Text in Illustration

Turn

• УКАЗАНИЕ:

• Fit the tips of SST onto the ribs of the retainer.

• ПРИМЕЧАНИЕ:

Remove the retainer.

Remove the fuel tank vent tube assembly from the fuel tank.

• ПРИМЕЧАНИЕ:

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

Remove the gasket from the fuel tank.

Remove the 2 bolts.

Detach the 4 clamps and remove the No. 3 fuel tank protector.

Remove the fuel tank to filler pipe hose from the fuel tank.

Disconnect the 2 fuel hoses.

Disconnect the level warning switch connector.

Remove the 2 nuts and fuel filter.

Loosen the fuel filter drain plug and drain the fuel from the fuel filter.

Detach the level warning switch connector clamp from the fuel filter cap.

Remove the 2 bolts, fuel filter case and fuel filter gasket.

Clamp the fuel filter cap in a vise between aluminum plates.

• ПРИМЕЧАНИЕ:

• Be careful not to damage the fuel filter cap.

Using pliers, remove the level warning switch.

• ПРИМЕЧАНИЕ:

• Be careful not to damage the level warning switch.

Remove the warning switch gasket from the level warning switch.

Using SST, remove the fuel filter element.

• SST
• 09228-64010

Check and clean the installation surface of the fuel filter element.

Apply fuel to the gasket of a new fuel filter element.

Lightly screw the fuel filter element into place, and tighten it until the gasket comes into contact with the seat.

Tighten the fuel filter element an additional 3/4 turn by hand.

Install a new level warning switch gasket to the level warning switch.

Apply fuel to the level warning switch gasket of the level warning switch.

Install the level warning switch to the fuel filter element and tighten it by hand.

• УКАЗАНИЕ:

• Install the level warning switch within the angle range shown in the illustration.

Install the fuel filter gasket and fuel filter case to the fuel filter element.

Tighten the 2 bolts.

• Момент затяжки:
• 3.4 N*m{ 35 kgf*cm, 30 in.*lbf}

• УКАЗАНИЕ:

• Install the level warning switch within the angle range shown in the illustration.

Attach the level warning switch connector clamp to the fuel filter cap.

Install the fuel filter with the 2 nuts.

• Момент затяжки:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Connect the level warning switch connector.

Connect the 2 fuel hoses.

Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

• УКАЗАНИЕ:

• When checking for fuel leaks, make sure that there is pressure in the fuel line.

Install 4 new injection nozzle seat gaskets and the 4 injection nozzle seats to the injection nozzle holes of the cylinder head.

Using SST, install the 4 nozzle holder and nozzle sets.

• SST
• 09268-64010(09268-64020)

• Момент затяжки:
• 64 N*m{ 650 kgf*cm, 47 ft.*lbf}

Install 4 new ring packing washers and the leakage pipe with the 4 nuts.

• Момент затяжки:
• 30 N*m{ 301 kgf*cm, 22 ft.*lbf}

Connect the fuel hose to the leakage pipe.

Install the No. 1 glow plug resistor insulator and No. 1 glow plug connector.

Install the glow plug connector with the 4 nuts. Uniformly tighten the nuts.

• Момент затяжки:
• 1.0 N*m{ 10 kgf*cm, 9 in.*lbf}

Install the 4 screw grommets.

Connect the engine wire and install the No. 2 glow plug resistor insulator and washer with the bolt.

• Момент затяжки:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the 2 lower clamps to the intake manifold.

Install the 4 injection pipes.

• Момент затяжки:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (See page ).

Install the 2 upper pipe clamps with the 2 nuts.

• Момент затяжки:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the diesel throttle body (See page ).

Move the hand pump on the upper part of the fuel filter up and down and fill the injection pump and fuel system with fuel.

Loosen one of the union nuts (on the nozzle side).

Crank the engine until fuel comes out from the union nut connection (on the nozzle side).

Tighten the union nut.

• Момент затяжки:
• 25 N*m{ 250 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (See page ).

Perform the procedures above for each injection pipe.

Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

• УКАЗАНИЕ:

• When checking for fuel leaks, make sure that there is pressure in the fuel line.

Install the pressure pin, distance piece and nozzle assembly to the nozzle retaining nut.

Install the nozzle holder pressure spring and adjusting shim, and then temporarily install the nozzle holder to the nozzle retaining nut.

Using SST, tighten the nozzle retaining nut.

• SST
• 09268-64010(09268-64020,09268-64030)

• Момент затяжки:
• 47 N*m{ 475 kgf*cm, 34 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Overtightening could cause nozzle deformation and needle adhesion or other defects.

Inspect the holder and nozzle set.

Install a new washer and the ring packing setting nut.

Pressure test:

Install the nozzle holder to an injection nozzle hand tester and bleed air from the union nut connection.

• ПРЕДОСТЕРЕЖЕНИЕ:

• Do not place your finger on the nozzle injection hole.

Pump the tester handle a few times as fast as possible to discharge the carbon from the injection hole.

Pump the tester handle slowly and observe the pressure gauge.

Read the pressure gauge just as the injection pressure begins to drop.

• Standard pressure:
• 15790 to 16570 kPa (161.0 to 169.0 kgf/cm², 2290 to 2403 psi)

• УКАЗАНИЕ:

It can be concluded that the nozzle is operating properly when a swishing sound is heard.

If the pressure is not within the standard, disassemble the nozzle holder and replace only the shim on the top of the pressure spring. Varying the adjusting shim thickness by 0.005 mm (0.000197 in.) changes the injection pressure by approximately 628 kPa (6.4 kgf/cm², 91 psi).

• Standard Adjusting Shim Thickness:

• Specified Condition
  0.900 mm (0.0354 in.)	1.300 mm (0.0512 in.)	1.700 mm (0.0669 in.)
  0.950 mm (0.0374 in.)	1.350 mm (0.0531 in.)	1.750 mm (0.0709 in.)
  1.000 mm (0.0394 in.)	1.400 mm (0.0551 in.)	1.800 mm (0.0728 in.)
  1.050 mm (0.0413 in.)	1.450 mm (0.0571 in.)	1.850 mm (0.0728 in.)
  1.100 mm (0.0433 in.)	1.500 mm (0.0591 in.)	1.900 mm (0.0748 in.)
  1.150 mm (0.0453 in.)	1.550 mm (0.0610 in.)	1.950 mm (0.0768 in.)
  1.200 mm (0.0472 in.)	1.600 mm (0.0630 in.)	-
  1.250 mm (0.0492 in.)	1.650 mm (0.0650 in.)	-

Leakage test:

Spray pattern test:

Using a wooden stick and brass brush, clean the nozzle.

• ПРИМЕЧАНИЕ:

• Do not touch the nozzle contact surface with your fingers.

Using a wooden stick, remove the carbon adhering to the nozzle needle tip.

Text in Illustration

*1	Wooden Stick

Using a brass brush, remove the carbon from the exterior of the nozzle body (except lapped surface).

Wash the nozzle in clean diesel fuel.

• ПРИМЕЧАНИЕ:

• Do not touch the nozzle contact surfaces with your fingers.

Perform the following test several times, rotating the needle slightly each time.

Remove the ring packing setting nut and washer.

Using SST, remove the nozzle retaining nut.

• SST
• 09268-64010(09268-64020,09268-64030)

• ПРИМЕЧАНИЕ:

• Be careful not to drop the inner parts.