Removal

2ZR-FE FUEL: FUEL TANK: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

(a) Remove the fuel suction tube assembly with pump and gauge from the fuel tank Removal.

4. DRAIN FUEL

5. REMOVE FRONT EXHAUST PIPE ASSEMBLY

HINT
Removal

6. REMOVE NO. 1 FUEL TANK PROTECTOR

(a) Remove the 4 bolts and the No. 1 fuel tank protector.





7. SEPARATE PARKING BRAKE CABLE

(a) Remove the 4 bolts, and separate the parking brake cables.





8. DISCONNECT FUEL TANK VENT HOSE

(a) Disconnect the fuel tank vent hose.





(b) Pull the fuel tank vent hose out of the pipe.

NOTICE:
* Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
* It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
* Only disconnect the quick connector by hand.
* Do not bend, kink or twist the nylon tubes.
* Protect the connector by covering it with a plastic bag.
9. DISCONNECT BREATHER TUBE FUEL HOSE

(a) Disconnect the breather tube fuel hose.





(1) Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.

NOTICE:
* Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
* It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
* Only disconnect the quick connector by hand.
* Do not bend, kink or twist the nylon tubes.
* Protect the connector by covering it with a plastic bag.
* If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
(b) Separate the fuel breather tube fuel hose.





10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Disconnect the fuel tank main tube.





(1) Pinch the tabs of the retainer of the fuel tube connector to disengage the lock claws and push it down as shown in the illustration.

(2) Pull the fuel tank main tube out of the pipe.

NOTICE:
* Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
* It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
* Only disconnect the quick connector by hand.
* Do not bend, kink or twist the nylon tubes.
* Protect the connector by covering it with a plastic bag.
* If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
11. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY

(a) Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.





(b) Loosen the hose clamp bolt, then disconnect the fuel tank filler pipe hose from the fuel tank.





12. REMOVE FUEL TANK ASSEMBLY

(a) Hold the fuel tank using a transmission jack.





(b) Remove the 4 bolts, then remove the 2 No. 1 fuel tank bands.





(c) Operate the transmission jack, then remove the fuel tank.

13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the fuel tank main tube from the fuel tank.





14. REMOVE FUEL TANK VENT HOSE

(a) Remove the fuel tank vent hose from the fuel tank clamp.





15. REMOVE FUEL TANK CUSHION

(a) Remove the fuel tank cushions from the fuel tank.