Removal
1GR-FE FUEL: FUEL TANK: REMOVAL
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT: Service Precautions
2. REMOVE REAR FLOOR SERVICE HOLE COVER
(a) Hold the rear No. 1 seat assembly LH.
(b) Hold the rear No. 1 seat assembly RH.
(c) Remove a tear-off floor mat.
(d) Remove the 3 screws from the rear floor service hole cover.
(e) Disconnect the connector.
3. REMOVE FUEL TANK TO FILLER PIPE HOSE
(a) Disconnect the fuel-tank-to-filler-pipe hose from the fuel filler pipe.
4. DRAIN FUEL
5. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
(a) Set a mission jack to the fuel tank protector.
(b) Remove the 6 bolts and the fuel tank protector.
6. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
(a) Pinch the tabs of the retainer to remove the lock claws and pull out the 2 fuel tank tubes.
NOTICE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube.
- To protect the tube, cover it with a vinyl bag after checking.
- When connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the fuel tank tube.
7. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY
(a) Pinch a tab of the retainer to remove the lock claws and pull out the fuel tank tube.
NOTICE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- To protect the tube, cover it with a vinyl bag after checking.
- When connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the tube.
8. DISCONNECT FUEL TANK VENT HOSE
(a) Disconnect the fuel tank breather tube from the fuel tank.
(1) Push the connector deep inside.
(2) Pinch portion A, as shown in the illustration.
(3) Pull out the connector.
9. REMOVE FUEL TANK ASSEMBLY
(a) Set a mission jack to the fuel tank.
(b) Remove the 2 bolts, 2 fuel tank bands and fuel tank.
10. REMOVE FUEL TANK CUSHION
11. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE
(a) Remove the 2 tubes joint clips, and pull out the 2 fuel tank tubes.
NOTICE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube joint with a vinyl bag.
- When the fuel tube joint and fuel suction plate are stuck, turn the fuel tank main tube carefully to free and then disconnect it. Likewise, disconnect the fuel tank return tube.
12. REMOVE FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY
NOTE: Protect a connector and tube joint with a masking tape or something in order to prevent sticking foreign objects onto them, and clean dirt and foreign objects from the fuel suction tube assembly before removing it.
(a) Using a SST, loosen the retainer.
SST: 09808-14020
HINT: A rib on the retainer can be fitted into a tip of the SST.
(b) Remove the retainer.
(c) Pull out the fuel suction tube assembly.
NOTE: Be careful not to bend the arm of the sender gage.
(d) Remove the gasket from the fuel tank.
13. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY
(a) Pinch the tab of the retainer to remove the lock claws and pull out the fuel tank breather tube.
NOTICE:
- Check that there is no dirt or mud around the quick connector before this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
- Do not use any tool in this work.
- Do not bend or twist the nylon tube.
- To protect the tube, cover it with a vinyl bag after checking.
- When connector and the pipe are stuck, turn the fuel tank breather tube carefully to free and then disconnect the tube.
14. REMOVE FUEL TANK TO FILLER PIPE HOSE
(a) Remove the fuel tank inlet hose from the fuel tank.