Removal

2GR-FSE FUEL: FUEL TANK: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
Service Precautions.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY Removal
4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER Removal
5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Removal
6. DRAIN FUEL
7. REMOVE REAR FLOOR SERVICE HOLE COVER





(a) Remove the rear floor service hole cover.
8. REMOVE FUEL SENDER GAUGE ASSEMBLY





(a) Disconnect the fuel sender gauge connector.





(b) Remove the 5 bolts and fuel sender gauge.
(c) Remove the fuel sender gauge from the fuel tank.
NOTE:
Be careful not to bend the arm of the fuel sender gauge.

9. REMOVE FRONT EXHAUST PIPE ASSEMBLY
HINT:
Removal.

10. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
HINT:
Removal.

11. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR Removal
12. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
HINT:
Removal procedure of the No. 1differential support protector is the same as that of the No. 2 differential support protector.

13. REMOVE REAR FLOOR SIDE MEMBER COVER LH
14. REMOVE REAR FLOOR SIDE MEMBER COVER RH
15. REMOVE REAR SUSPENSION MEMBER BRACE LH





(a) Remove the 4 bolts and suspension member brace lower LH.
16. REMOVE REAR SUSPENSION MEMBER BRACE RH





(a) Remove the 4 bolts and suspension member brace lower RH.
17. DISCONNECT PARKING BRAKE CABLE ASSEMBLY





(a) Remove the 2 parking brake cables from the 4 clamps.
(b) Remove the 4 bolts and disconnect the 2 parking brake cables.
18. DISCONNECT FUEL TUBE SUB-ASSEMBLY





(a) Disconnect the fuel tank main tube (LH side).
- Remove any dirt and foreign objects on 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 O-rings that seal 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 plastic bag after disconnecting the fuel pump tube.
- If the fuel tube connector and pipe are stuck, push and pull on them to release them.





(b) Disconnect the fuel tank return vent tube.
- Remove any dirt and foreign objects on 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 O-rings that seal 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 plastic bag after disconnecting the fuel pump tube.
- If the fuel tube connector and pipe are stuck, push and pull on them to release them.





(c) Disconnect the fuel tank main tube (RH side).
- Remove any dirt and foreign objects on 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 O-rings that seal 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 plastic bag after disconnecting the fuel pump tube.
- If the fuel tube connector and pipe are stuck, push and pull on them to release them.

19. DISCONNECT FUEL TANK TO FILLER PIPE HOSE





(a) Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
20. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY





(a) Disconnect the fuel hose clamp.
(b) Remove the clip and disconnect the No. 3 fuel hose sub-assembly.
21. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY





(a) Disconnect the fuel tube clamp.
(b) Disconnect the fuel tank to canister tube sub-assembly.
NOTICE:
- Remove any dirt and foreign objects on 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 O-rings that seal 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 plastic bag after disconnecting the fuel pump tube.
- If the fuel tube connector and pipe are stuck, push and pull on them to release them.

22. REMOVE FUEL TANK ASSEMBLY





(a) Place a engine lifter under the fuel tank assembly.
(b) Remove the 4 bolts, fuel tank bands and fuel tank assembly.
23. REMOVE NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY





(a) Remove the 4 bolts, No. 1 fuel tank breather tube sub-assembly and gasket.
24. REMOVE FUEL TUBE SUB-ASSEMBLY





(a) Disconnect the clamp and remove the fuel tank main tube and fuel tank return vent tube.





(b) Disconnect the 2 clamps and remove the edge protector.
25. REMOVE FUEL TANK TO FILLER PIPE HOSE





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





(a) Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
(b) Pinch portion A.
(c) Pull out the fuel tank vent hose.
(d) Remove the fuel vapor containment valve from the fuel tank.
27. REMOVE FUEL TANK CUSHION





(a) Remove the 11 fuel tank cushions shown in the illustration.
28. REMOVE NO. 2 FUEL TANK PROTECTOR





(a) Remove the No. 2 fuel tank protector from the fuel tank assembly.