Removal

1GR-FE FUEL: FUEL TANK: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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) Disconnect the fuel tank main tube Service Precautions.

5. DISCONNECT FUEL TANK RETURN TUBE





(a) Disconnect the fuel tank return tube Service Precautions.

6. DISCONNECT VENT LINE HOSE

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





Text in Illustration





NOTICE:
* 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.

7. DISCONNECT WIRE HARNESS

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





8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE





(a) Disconnect the fuel tank breather tube Service Precautions.

(b) Disconnect the fuel tank to filler pipe hose from the inlet pipe.

(c) Detach the filler pipe hose and breather tube from the No. 1 breather tube clamp.

9. 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.

10. REMOVE FUEL TANK ASSEMBLY

(a) Set a engine lifter underneath the fuel tank.

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





(c) Slowly lower the engine lifter slightly.

NOTICE:
Be careful not to cut the wiring.

(d) Detach the wire harness clamp from the fuel tank as shown in the illustration.





(e) Disconnect the fuel pump connector and lower the engine lifter.

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

11. REMOVE FUEL TANK INLET PIPE SUB-ASSEMBLY

(a) Remove the 2 nuts and inlet pipe.





12. REMOVE NO. 1 FUEL TANK HEAT INSULATOR

(a) Remove the nut from the heat insulator.





Text in Illustration





(b) Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the heat insulator.

13. REMOVE FUEL TANK TO FILLER PIPE HOSE

(a) Remove the filler pipe hose from the fuel tank.





14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

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





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.

Text in Illustration





(b) Using SST, loosen the retainer.

SST : 09808-14020





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

NOTICE:
* 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.

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

(e) Remove the gasket from the fuel tank.