From 08/2009

2GR-FE FUEL: FUEL TANK: REMOVAL

1. PRECAUTION (w/ Air Suspension)

NOTICE:
Be sure to read Precaution thoroughly before servicing Suspension Control System.

2. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

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

3. DRAIN FUEL

4. REMOVE FRONT CENTER FLOOR COVER

5. REMOVE TAIL EXHAUST PIPE ASSEMBLY (for 2WD) Removal

6. REMOVE REAR SUSPENSION MEMBER (for AWD)

(a) Remove the rear suspension member Removal.

7. REMOVE CHARCOAL CANISTER PROTECTOR Removal

8. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Remove the 3 clips (A) and 7 nuts, and then remove the No. 1 fuel tank protector sub-assembly.





9. REMOVE FUEL TANK ASSEMBLY

(a) Disconnect the fuel tank main tube sub-assembly.





Text in Illustration





(1) Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.

(2) Pull out the fuel tank main tube sub-assembly.

NOTICE:
* Check if there is any dirt or mud around the connector before this operation and clean the connector if necessary.
* It is necessary to prevent mud or dirt from entering the quick connector. If any foreign objects enter the connector, the O-rings may not seal properly.
* Do not use any tools in this operation.
* Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
* When the pipe and connector are stuck, push and pull the connector to release it and pull the connector out carefully.
(b) Disconnect the fuel tank vent hose from the charcoal canister assembly.





NOTICE:
* Remove dirt or foreign objects on the quick connector before this work.
* Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel 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 connected part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
* If the quick connector and pipe are stuck, push and pull them to release.
(c) Disconnect the No. 3 fuel tank breather tube.





(1) Pull the checker of the breather tube connector.

(2) Pinch the retainer of the breather tube connector to disconnect the No. 3 fuel tank breather tube from the fuel tank.

NOTICE:
* Check if there is any dirt or mud around the connector before this operation and clean the connector as necessary.
* It is necessary to prevent mud or dirt from entering the quick connector. If any foreign objects enter the connector, the O-rings may not seal properly.
* Do not use any tools in this operation.
* Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
* When the pipe and connector are stuck, push and pull the connector to release it and pull the connector out carefully.
(d) Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.





(e) Remove the bolt and nut, and then remove the rear fuel tank bracket LH.





(f) Remove the bolt.





(g) Set a engine lifter under the fuel tank.





(h) Remove the 4 bolts, and then remove the 2 fuel tank bands.

(i) Operate the transmission jack to remove the fuel tank.

10. REMOVE NO. 2 FUEL TANK SIDE PLATE

(a) Remove the No. 2 fuel tank side plate.





11. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Release the 2 claws, and then remove the fuel pump tube.





Text in Illustration





12. REMOVE FUEL TANK TO FILLER PIPE HOSE

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





13. REMOVE FUEL TANK CUSHION SET

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





Text in Illustration





14. REMOVE TANK SUCTION TUBE SUPPORT

(a) Remove the tank suction tube support from the fuel tank.