Removal

2UZ-FE FUEL TANK:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE (Removal)

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
- Some systems need to be initialized after the cable is reconnected (Repair Instruction - Initialization).
- After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.

3. REMOVE FUEL TANK CAP
4. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (for Rough Road Area Specification Vehicles)
(a) Remove the 2 bolts, 2 nuts and tank protector.





5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Detach the lock claw by lifting up the cover, as shown in the illustration.
(b) Pinch and pull the main tube connector to disconnect the connector from the pipe.

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.





6. DISCONNECT FUEL TANK RETURN TUBE
(a) Detach the lock claw by lifting up the cover, as shown in the illustration.
(b) Pinch and pull the return tube connector to disconnect the connector from the pipe.

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.

7. DISCONNECT VENT LINE HOSE





(a) Pull up the retainer and disconnect the vent line hose.

- Do not use any tools in this procedure.

- Check for any dirt and foreign matter contamination in the valve and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the valve and connector.

8. DISCONNECT WIRE HARNESS





(a) Detach the harness clamp from the fuel tank.





9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Detach the lock claw by lifting up the cover, as shown in the illustration.
(b) Disconnect the fuel tank breather tube from the inlet pipe.
(c) Disconnect the fuel tank to filler pipe hose from the inlet pipe.
(d) Detach the filler pipe hose and breather tube from the No. 1 breather tube clamp.
10. DISCONNECT NO. 1 CANISTER OUTLET HOSE
(a) Disconnect the canister outlet hose from the inlet pipe.
(b) Detach the hose from the No. 1 breather tube clamp.
11. REMOVE FUEL TANK ASSEMBLY
(a) Set a mission jack underneath the fuel tank.





(b) Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.
(c) Slowly lower the mission jack slightly.

NOTE: Be careful not to cut the wirings.





(d) Detach the wire harness clamp from the fuel tank as shown in the illustration.
(e) Disconnect the fuel pump connector and lower the mission jack.

NOTICE:
- Before this procedure, check the connector for dirt, mud or other contamination.
- Do not use any tools in this procedure.

12. REMOVE FUEL TANK INLET PIPE SUB-ASSEMBLY





(a) Remove the 2 nuts and inlet pipe.





13. REMOVE NO. 1 FUEL TANK HEAT INSULATOR
(a) Remove the nut from the heat insulator.
(b) Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the heat insulator.
14. REMOVE FUEL TANK TO FILLER PIPE HOSE





(a) Remove the filler pipe hose from the fuel tank.
15. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY





(a) Remove the 2 tube joint clips and pull out the 2 fuel tank tubes.

- 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) Using SST, loosen the retainer.
SST: 09808-14020
09808-01410
09808-01420
09808-01430

HINT: Fit the tips of SST onto the ribs of the retainer.

- When the retainer is loosened, be careful as the pump and gauge tube will spring upward from the force of the spring.
- Clean the pump and gauge tube before this operation.

(c) Remove the retainer.
(d) Remove the fuel suction with pump and gauge tube assembly from the fuel tank.

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

(e) Remove the gasket from the fuel tank.