Removal
3UR-FE FUEL: FUEL TANK: REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE Removal
2. REMOVE FUEL TANK CAP ASSEMBLY
3. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
(a) Remove the 5 bolts and fuel tank protector.
4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Detach the fuel tube clamp.
(b) Disconnect the fuel tank main tube.
NOTICE:
* Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
* Do not use any tools to separate the pipe and connector.
* Do not forcefully bend or twist the nylon tube.
* Check for foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
* If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
5. DRAIN FUEL
(a) Connect the cable to the negative (-) battery terminal.
(b) Connect the Techstream to the DLC3.
(c) Turn the engine switch on (IG).
NOTICE:
Do not start the engine.
(d) Turn the Techstream main switch on.
(e) Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
CAUTION:
* Do not smoke or be near an open flame when working on the fuel system.
* Secure good ventilation.
* Keep gasoline away from rubber or leather parts.
HINT
If the fuel pump does not operate, remove the fuel tube joint clip and No. 1 fuel tube joint, and drain fuel from the port shown in the illustration.
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
7. REMOVE REAR NO. 1 SEAT ASSEMBLY LH
(a) Remove the rear No. 1 seat assembly Removal.
8. REMOVE REAR NO. 1 SEAT ASSEMBLY RH
(a) Remove the rear No. 1 seat assembly Removal.
9. REMOVE REAR NO. 1 SEAT PROTECTOR Removal
10. REMOVE REAR NO. 2 SEAT PROTECTOR Removal
11. REMOVE REAR STEP COVER Removal
12. REMOVE REAR DOOR SCUFF PLATE LH Removal
13. REMOVE REAR DOOR SCUFF PLATE RH Removal
14. REMOVE REAR NO. 2 SEAT ASSEMBLY
(a) Remove the rear No. 2 seat assembly Removal.
15. REMOVE REAR FLOOR MAT REAR SUPPORT PLATE Removal
16. REMOVE LUGGAGE COMPARTMENT NO. 1 TRIM HOOK Removal
17. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH Removal
18. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH Removal
19. REMOVE AIR DUCT PLUG Removal
20. REMOVE REAR AIR DUCT GUIDE Removal
21. REMOVE FRONT FLOOR CARPET ASSEMBLY
(a) Fold back the floor carpet.
HINT
Fold back the carpet until it is possible to remove the air duct.
22. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER
(a) Remove the 2 screws and air duct.
(b) Remove the service hole cover.
(c) Disconnect the fuel pump and fuel sender gauge connector.
23. DISCONNECT FUEL TANK RETURN TUBE
(a) Detach the fuel tube clamp.
(b) Disconnect the fuel tank return tube.
NOTICE:
* Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
* Do not use any tools to separate the pipe and connector.
* Do not forcefully bend or twist the nylon tube.
* Check for foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
* If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
24. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
(a) Detach the 2 fuel tube clamps.
(b) Disconnect the No. 2 fuel tank breather tube.
NOTICE:
* Do not use any tools in this procedure.
* Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
25. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY
(a) Detach the fuel tube clamp.
(b) Disconnect the fuel tank breather tube.
NOTICE:
* Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
* Do not use any tools to separate the pipe and connector.
* Do not forcefully bend or twist the nylon tube.
* Check for foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
* If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
26. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Disconnect the fuel tank to filler pipe hose from the fuel tank filler pipe.
27. REMOVE FUEL TANK SUB-ASSEMBLY
(a) Place a transmission jack under the fuel tank.
(b) Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.
(c) Slowly lower the transmission jack slightly.
28. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY
(a) Remove the 3 fuel tube joint clips and pull out the 2 fuel tubes and No. 1 fuel tube joint.
NOTICE:
* Remove any dirt and foreign matter on the fuel tube joint before performing this step.
* Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
* Perform this step by hand. Do not use any tools.
* Do not forcibly bend, twist or turn the nylon tube.
* Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
(b) Remove the fuel main tube and fuel return tube from the fuel tank.
29. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
(a) Using SST, loosen the retainer.
SST : 09808-14020
HINT
Fit the tips of SST onto the ribs of the retainer.
NOTICE:
* When the retainer is loosened, be careful as the pump and gauge tube will spring upward from the force of the spring.
* Remove foreign matter around the fuel suction with pump and gauge before this operation.
(b) Remove the retainer.
(c) Remove the fuel suction with pump and gauge tube assembly from the fuel tank.
NOTICE:
Be careful not to bend the arm of the fuel sender gauge.
(d) Remove the gasket from the fuel tank.
30. REMOVE FUEL TANK TO FILLER PIPE HOSE
(a) Remove the fuel tank to filler pipe hose from the fuel tank.
31. REMOVE NO. 1 FUEL TANK HEAT INSULATOR
(a) Remove the fuel tube clamp from the No. 1 fuel tank heat insulator.
(b) Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the No. 1 fuel tank heat insulator.