Removal

2GR-FE FUEL TANK: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
Service Precautions.

2. REMOVE DECK BOARD SUB-ASSEMBLY Removal

3. REMOVE REAR SEAT ASSEMBLY RH
.

4. REMOVE REAR SEAT ASSEMBLY LH
.

5. REMOVE REAR DOOR SCUFF PLATE LH

6. REMOVE DECK SIDE TRIM COVER LH

7. REMOVE REAR SEAT SIDE COVER LH

8. REMOVE REAR FLOOR SERVICE HOLE COVER Removal

9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Removal

10. DRAIN FUEL
11. REMOVE NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover)
12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) Removal

13. REMOVE EXHAUST CENTER PIPE ASSEMBLY
Removal.

14. REMOVE NO. 3 FRONT FLOOR HEAT INSULATOR Removal

15. REMOVE NO. 4 EXHAUST PIPE SUPPORT BRACKET (for 4WD)

(a) Remove the 2 bolts, and then remove the No. 4 exhaust pipe support bracket.
16. REMOVE NO. 1 FUEL TUBE PROTECTOR

(a) Remove the 2 clips and unfasten the claw, and then remove the No. 1 fuel tube protector.
17. REMOVE NO. 1 FUEL TANK PROTECTOR

(a) Remove the 4 nuts, and then remove the No. 1 fuel tank protector.
18. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Remove the 3 clips (A) and 6 nuts, and then remove the No. 1 fuel tank protector.
19. REMOVE FUEL TANK ASSEMBLY

(a) Disconnect the fuel pump tube.
(1) Pinch the projection of the retainer to remove the lock claws and pull it down as shown in the illustration.
(2) Pull out the fuel pump tube.
NOTICE:
- Check if there is any dirt or mud around the connector before this operation and remove the dirt if necessary.
- Be careful of mud because the quick connector can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.

(b) Disconnect the fuel tank vent hose.
(1) Deeply push the connector to release the locking tab.
(2) Pinch portion A.
(3) Pull out the connector.

(c) Disconnect the No. 3 fuel tank breather tube.
(1) Pinch the tube connector and then pull out the No. 3 fuel tank breather tube.
NOTICE:
- Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.

(d) Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
(e) Set up a transmission jack under the fuel tank.
(f) Remove the 4 bolts, and then remove the 2 fuel tank bands.
(g) Remove the 2 nuts.
(h) Operate the transmission jack to remove the fuel tank.

20. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY

(a) Unfasten the 2 claws, and then remove the fuel pump tube.
21. REMOVE FUEL TANK TO FILLER PIPE HOSE

(a) Loosen the hose clamp bolt, and then remove the fuel tank to filler pipe hose.
22. REMOVE FUEL TANK VENT HOSE

(a) Completely push the connector to release the locking tab (*1).
(b) Pinch portion A (*2).
(c) Pull out the connector.
(d) Unfasten the claw, and then remove the fuel tank vent hose.

(e) Disconnect the No. 1 evaporation vent tube.
- Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
- Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
- Do not use any tool in this operation.
- Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
- When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.

23. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSEMBLY

(a) Using SST, loosen the fuel pump gauge retainer.
SST: 09808-14020
09808-01410
09808-01420
09808-01430
NOTE: Loosen the retainer by turning it counterclockwise while holding the SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.
HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.

(b) Remove the fuel pump gauge retainer.

(d) Remove the tank suction tube support and gasket from the fuel tank.
24. REMOVE TANK SUCTION TUBE SUPPORT

(a) Remove the tank suction tube support from the fuel tank.
25. REMOVE FUEL TANK SIDE PLATE

(a) Remove the bolt and nut, and then remove the fuel tank side plate and the fuel tank bracket.
26. REMOVE FUEL TANK CUSHION SET

(a) Remove the fuel tank cushion sets and No. 5 fuel tank cushions.