Removal

2AZ-FE FUEL: FUEL TANK: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
HINT: Technician Safety Information.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) Removal
4. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type) Removal
5. REMOVE REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type) Removal
6. REMOVE REAR FLOOR SERVICE HOLE COVER Removal
7. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY Removal
8. REMOVE FUEL TANK VENT TUBE SET PLATE Removal
9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Removal
10. DRAIN FUEL
11. REMOVE CENTER EXHAUST PIPE ASSEMBLY Removal
12. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY





(a) Remove the set bolt and set nut of the No. 2 parking brake cable assembly.
13. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY





(a) Remove the set bolt and set nut of the No. 3 parking brake cable assembly.
14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET





(a) Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets.
15. REMOVE FUEL TANK PROTECTOR LOWER CENTER





(a) Remove the 4 bolts and fuel tank protector (Except SE Grade).





(b) Remove the 4 bolts and 2 clips (for SE Grade).
(c) Remove the fuel tank protector (for SE Grade).
16. REMOVE FUEL TANK ASSEMBLY





(a) Disconnect the fuel pump tube.
(1) Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.
(2) Pull out the fuel tank main tube.
NOTICE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Only disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.

(b) Disconnect the No. 1 fuel tube.




(1) Pinch the tube connector and then pull out the No. 1 fuel tube.
NOTICE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
- Only disconnect the quick connector by hand.
- Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
- If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.





(c) Place a transmission jack under the fuel tank assembly.





(d) Remove the 2 set bolts of the fuel tank bands.





(e) Remove the clamp and disconnect the fuel tank to filter pipe hose (except PZEV).





(f) Remove the clamp and disconnect the fuel tank to filter pipe (for PZEV).
NOTICE:
- Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
- It is necessary to prevent mud or dirt from entering the fuel filler pipe. If mud or dirt gets in the fuel filler pipe, the O-rings may not seal properly.
- Remove the fuel filler pipe by hand.
- Protect the fuel filler pipe by covering it with a plastic bag.
- If the fuel filler pipe and fuel tank are stuck, carefully try wiggling or pushing and pulling on the fuel filler pipe to release it. Pull the fuel filler pipe off the fuel tank carefully.

(g) Slightly lower the transmission jack.





(h) Disconnect the fuel tank vent hose from the charcoal canister.
(1) Push the connector deep into the charcoal canister to release the locking pin.
(2) Pinch portion A.
(3) Pull out the connector.
(i) Remove the fuel tank.





(j) Remove the 2 pins and 2 fuel tank bands as shown in the illustration.





(k) Remove the 4 clip nuts (Except SE Grade).





(l) Remove the 4 clip nuts (for SE Grade).
17. REMOVE FUEL TANK VENT HOSE





(a) Push the connector deep into the charcoal canister to release the locking pin.
(b) Pinch portion A.
(c) Pull out the connector.
18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY





(a) Remove the fuel pump tube from the fuel main tube support.
19. REMOVE FUEL MAIN TUBE SUPPORT





(a) Remove the bolt and tube support.
20. REMOVE NO. 2 FUEL TANK CUSHION





(a) Remove the 7 No. 2 fuel tank cushions.