Removal

2TR-FE FUEL: FUEL TANK: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

3. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE





(a) Remove the fuel pipe clamp.

(b) Disconnect the fuel tank main tube and fuel tank return tube.





(1) Pinch the retainer as illustrated, then pull the fuel tube connectors out of the pipes.

NOTICE:
* Remove any dirt and foreign objects from the fuel tube connector before performing this work.
* Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
* Perform this work 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 vinyl bag after disconnecting the fuel tube.
* If the fuel tube connector and pipe are stuck, push and pull to release them.
4. REMOVE FUEL TANK ASSEMBLY





(a) Loosen the clamp bolt.

(b) Disconnect the fuel breather tube.

(1) Remove the checker of the fuel tube connector from the pipe.

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

NOTICE:
* Remove any dirt and foreign objects from the fuel tube connector before performing this work.
* Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
* Perform this work 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 vinyl bag after disconnecting the fuel tube.
* If the fuel tube connector and pipe are stuck, push and pull to release them.
(c) Hold the fuel tank using the mission jack.

(d) Remove the 2 fuel tank bands.





(1) Remove the 2 bolts.

(2) Remove the 2 clips and 2 pins, then remove the 2 fuel tank bands.

(e) Remove the fuel pump cover.

(f) Slightly jack the fuel tank down and separate the fuel tank to filler pipe hose from the inlet pipe.

NOTICE:
Slowly jack down the fuel tank so as not to tear the wire harness and hose.

(g) Disconnect the fuel pump connector.

(h) Disconnect the fuel tank vent hose.

(1) Pinch the retainer and pull the fuel tank vent hose connector out of the charcoal canister to disconnect the fuel tank vent hose from the charcoal canister.

NOTICE:
* Remove any dirt and foreign objects from the fuel tank vent hose connector before performing this work.
* Do not allow any scratches of foreign objects on the parts when disconnecting, as the fuel tank vent hose connector has the O-ring that seals the pipe.
* Perform this work 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 vinyl bag after disconnecting the fuel tank vent hose.
* If the fuel tank vent connector and pipe are stuck, push and pull to release them.
(i) Remove the fuel tank assembly.





5. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE





(a) Remove the 2 joint clips, then remove the fuel tank main tube and fuel tank return tube.

NOTICE:
* Remove any dirt and foreign objects from the fuel tube connector before performing this work.
* Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
* Perform this work 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 vinyl bag after disconnecting the fuel tube.
* If the fuel tube connector and pipe are stuck, push and pull to release them.
6. REMOVE FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY





NOTICE:
Protect the connector and tube joint with masking tape or equivalent to prevent any foreign objects from sticking to them. Clean any dirt and foreign objects from the fuel suction tube assembly before removing.

(a) Using a SST, loosen the retainer.

SST : 09808-14020

09808-01410

09808-01420

09808-01430

HINT
The ribs on the retainer can be fitted into a tip of the SST.

(b) Remove the retainer.

(c) Pull the fuel pump assembly out of the fuel tank.

NOTICE:
Be careful not to bend the arm of the sender gauge.

(d) Remove the gasket from the fuel tank.





7. DRAIN FUEL

8. REMOVE FUEL TANK TO FILLER PIPE HOSE





(a) Loosen the clamp bolt, then remove the fuel tank to filler pipe hose.

9. REMOVE NO. 1 FUEL TANK PROTECTOR

(a) Remove the 4 clips, then remove the fuel tank protector.