Fuel Tank: Service and Repair

Fuel Tank Assy (2UZ-FE):

Removal & Installation and Disassembly & Reassembly
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE REAR N0.1 SEAT ASSY LH
3. REMOVE REAR FLOOR STEP COVER N0.1
4. REMOVE QUARTER SCUFF PLATE INSIDE LH
a. Remove the 2 bolts and quarter scuff plate inside LH.

5. REMOVE REAR DOOR SCUFF PLATE LH

6. REMOVE REAR FLOOR SERVICE HOLE COVER
a. Hold the rear No. 1 seat assy LH.
b. Hold the rear No. 1 seat assy RH.
c. Remove a tear-off floor mat.
d. Remove the 3 screws from the center floor hole cover.
e. Disconnect the 2 connectors.

7. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Disconnect the fuel-tank-to-filler-pipe-hose from the fuel filler pipe.

8. DRAIN FUEL
9. REMOVE FUEL TANK PROTECTOR SUB-ASSY N0.1
a. Set a mission jack to the fuel tank protector.
b. Remove the 6 bolts and the fuel tank protector.

10. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Pinch the projections of the retainer to remove the lock claws and pull out the 2 fuel tank tubes.

NOTE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- To protect the tube, cover it with a vinyl bag after checking.
- When connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the fuel tank tube.

11. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSY
a. Pinch the projections of the retainer to remove the lock claws and pull out the fuel tank tube.

NOTE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- To protect the tube, cover it with a vinyl bag after checking.
- When connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the tube.

12. DISCONNECT FUEL TANK VENT HOSE
a. Disconnect the fuel tank breather tube from the fuel tank.
1. Push the connector deep inside.
2. Pinch portion A.
3. Pull out the connector.

13. REMOVE FUEL TANK ASSY
a. Set a mission jack to the fuel tank.
b. Remove the 2 bolts, 2 fuel tank bands and fuel tank.

14. REMOVE FUEL TANK CUSHION

15. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Remove the 2 tubes joint clips, and pull out the 2 fuel tank tubes.

NOTE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube joint with a vinyl bag.
- When the fuel tube joint and fuel suction plate are stuck, turn the fuel tank main tube carefully to free and then disconnect it. Likewise, disconnect the fuel tank return tube.

16. REMOVE FUEL SUCTION W/PUMP & GAGE TUBE ASSY

NOTE: Protect a connector and tube joint with a making tape or something in order to prevent sticking foreign objects onto them, and clean dirt and foreign objects from the fuel suction tube assy before removing it.

a. Using a SST, loosen the retainer.

SST 09808-14020(09808-01410, 09808-01420, 09808-01430)

HINT: A rib on the retainer can be fitted into a tip of the SST.

b. Remove the retainer.
c. Pull out the fuel suction tube assy.

NOTE: Be careful not bend the arm of the sender gage.

d. Remove the gasket from the fuel tank.

17. REMOVE FUEL TANK BREATHER TUBE SUB-ASSY
a. Pinch the projections of the retainer to remove the lock claws and pull out the fuel tank breather tube.

NOTE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- To protect the tube, cover it with a vinyl bag after checking.
- When connector and the pipe are stuck, turn the fuel tank breather tube carefully to free and then disconnect the tube.

18. REMOVE FUEL TANK TO FILLER PIPE HOSE
a. Remove the fuel tank inlet hose from the fuel tank.

19. INSTALL FUEL TANK TO FILLER PIPE HOSE
a. Hose and pipe connection is as shown in the illustration.

NOTE: The filler hose must be replaced to new one.

20. INSTALL FUEL TANK BREATHER TUBE SUB-ASSY
a. Push in the tube connector to the pipe until the connector makes a "click" sound and install the retainer.

NOTE:
- Check if there is any damage or foreign objects on the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.

21. INSTALL FUEL SUCTION W/PUMP & GAGE TUBE ASSY
a. Install a new gasket onto the fuel tank.
b. Set the fuel suction tube assy to the fuel tank.

NOTE: Be careful not bend the arm of the fuel sender gage.

c. Fit a spline of the fuel suction tube assy into a keyway of the fuel tank.

d. Install a retainer.
1. Using a new retainer, align mark on the retainer with a screw-threads starting point of the fuel tank.
2. While holding the fuel suction tube assy, tighten the retainer one complete turn by hand.

e. Using a SST, tighten the retainer one more complete turn, and position the mark on the retainer into a range A of the fuel tank.

SST 09808-14020 (09808-01410,09808-01420, 09808-01430)

HINT:
- Turn the retainer two complete turns and position the mark within the range A for the installation of the retainer.
- A rib on the retainer can be fitted into a tip of the SST.

22. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Connect the 2 fuel tank tubes with the tube joint clips.

NOTE:
- Check that there is no scratch or foreign objects on the connecting parts.
- Check that the connector is fully inserted.
- Check that the tube joint clip is on the collar of the connector.
- After installing the tube joint clip, check if the tubes are securely connected by puling then.

23. INSTALL FUEL TANK CUSHION
a. Install the 3 new fuel tank cushions to the fuel tank.

24. INSTALL FUEL TANK ASSY
a. Set a mission jack to the fuel tank.
b. Install the fuel tank and 2 fuel tank bands with the 2 bolts.

Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)

25. CONNECT FUEL TANK BREATHER TUBE SUB-ASSY
a. Push in the tube connector to the pipe until the connector makes "click" sound.

NOTE:
- Check that there is no damage or foreign objects on the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.

26. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
a. Push in the tube connector to the pipe until the connector makes "click" sound.

NOTE:
- Check that there is no damage or foreign objects on the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.

27. INSTALL FUEL TANK PROTECTOR SUB-ASSY N0.1
a. Set a mission jack to the fuel tank protector.
b. Install the fuel tank protector with the 6 bolts.

Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)

28. CONNECT FUEL TANK TO FILLER PIPE HOSE
a. Hose and pipe connection is as shown in the illustration.

29. CHECK FUEL LEAK