Removal
2GR-FSE FUEL: FUEL TANK: REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE Removal
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE REAR SEAT CUSHION ASSEMBLY Removal
4. REMOVE ROOM NO. 3 PARTITION PAD Removal
5. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER Removal
6. REMOVE FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY Removal
7. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Remove the service hole cover and disconnect the fuel sender gauge connector.
8. REMOVE FUEL RETURN VENT TUBE SUB-ASSEMBLY
(a) Disconnect the fuel return tube.
Remove the tube joint clip and fuel tube.
NOTICE:
* Remove any dirt and foreign matter on the fuel tube joint before performing this work.
* 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 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 and tape after disconnecting the fuel tubes.
(b) Loosen the fuel pump gauge retainer.
NOTICE:
Use SST. Do not use any other tools such as a screwdriver.
Using a 6 mm socket, set SST to the fuel pump gauge retainer.
SST : 09808-14020
HINT
Fit the tips of SST on the ribs of the retainer.
(1) Using SST, loosen the fuel gauge retainer.
Hold SST with one hand and use SST, remove the fuel pump gauge retainer.
Remove the fuel return vent tube sub-assembly from the fuel tank.
NOTICE:
Be careful not to bend the arm of the sender gauge.
(c) Remove the gasket.
Disconnect the fuel sender gauge connector.
(d) Press down on the sender gauge claw labeled A. Then slide the sender gauge upward.
9. REMOVE EXHAUST PIPE ASSEMBLY
(a) Remove the exhaust pipe Removal.
10. REMOVE FRONT FLOOR COVER CENTER RH
(a) Remove the 3 nuts, 2 clips and floor cover.
11. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR
(a) Remove the 4 nuts and heat insulator.
12. REMOVE AIR GUIDE PLATE OUTSIDE RH Removal
13. REMOVE REAR PROPELLER SHAFT ASSEMBLY (for 2WD) Removal
14. REMOVE REAR PROPELLER SHAFT ASSEMBLY (for 4WD) Removal
15. REMOVE NO. 2 FUEL TANK PROTECTOR
(a) Remove the 4 nuts and fuel tank protector.
16. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
(a) Remove the 2 nuts and differential support protector.
17. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
(a) Remove the 2 nuts and differential support protector.
18. REMOVE REAR FLOOR SIDE MEMBER COVER LH
(a) Remove the 2 bolts and member cover.
19. REMOVE REAR FLOOR SIDE MEMBER COVER RH
(a) Remove the 2 bolts and member cover.
20. 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.
21. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
Disconnect the fuel tank main tube RH.
NOTICE:
* Check for any dirt and foreign matter contamination 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 any dirt and foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
* If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
Disconnect the fuel tank main tube LH.
NOTICE:
* Check for any dirt and foreign matter contamination 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 any dirt and foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
* If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
22. DISCONNECT FUEL RETURN TUBE
(a) Pinch and pull the return tube connector to disconnect the connector from the pipe.
23. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Loosen the clamp and disconnect the filler pipe hose from the fuel tank filler pipe.
24. DISCONNECT FUEL EMISSION HOSE
(a) Disconnect the fuel tank bracket hose.
(b) Disconnect the 2 fuel emission hoses.
25. REMOVE FUEL TANK SUB-ASSEMBLY
(a) Remove the 2 nuts from the fuel tank.
(b) Place a mission jack under the fuel tank.
(c) Remove the 4 bolts and 2 fuel tank bands.
26. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Detach the fuel tank main tube from the clamps, and remove it.
27. REMOVE FUEL RETURN TUBE
28. REMOVE FUEL TANK CUSHION
(a) Remove the tank cushions and fuel tank brackets.
29. REMOVE NO. 1 FUEL TANK PROTECTOR
(a) Remove the 2 nuts and fuel tank protector.