Removal

1UR-FE 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 disable the SRS system.

NOTICE:
When disconnecting the cable some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

3. REMOVE FUEL TANK CAP

4. 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 fuel tank main tube sub-assembly 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.

5. 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 fuel tank return tube 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. REMOVE FUEL TANK ASSEMBLY

(a) Disconnect the fuel tank to filler pipe hose from the fuel tank assembly.





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





(c) Detach the lock claw by lifting up the cover, as shown in the illustration.





(d) Disconnect the fuel tank breather tube from the fuel tank inlet pipe sub-assembly.

(e) Set a transmission jack underneath the fuel tank assembly.





(f) Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.

(g) Slowly lower the transmission jack slightly.

NOTICE:
Be careful not to cut the wiring.

(h) Disconnect the wire harness clamp from the fuel tank assembly.





(i) Disconnect the fuel pump connector and lower the transmission jack.

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

7. 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 No. 1 fuel tank heat insulator.

8. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Removal