Removal

2AZ-FE FUEL: FUEL TANK: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
(a) Discharge fuel system pressure Technician Safety Information.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FUEL SUCTION TUBE ASSEMBLY
(a) Remove the fuel suction tube assembly from the fuel tank assembly Removal.
4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER (for 4WD) Removal
5. REMOVE FUEL SENDER GAUGE RH ASSEMBLY (for 4WD) Removal
6. DRAIN FUEL
7. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 4WD)
HINT: Removal

8. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2WD)
HINT: Removal

9. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
10. SEPARATE PARKING BRAKE CABLE





(a) Remove the 4 bolts, and separate the parking brake cables.
11. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY (for 4WD)





(a) Remove the 4 bolts and 2 nuts, then remove the fuel tank protector sub-assembly.
12. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY (for 2WD)





(a) Remove the 4 bolts and the fuel tank protector sub-assembly.
13. REMOVE CHARCOAL CANISTER ASSEMBLY (for Double Wishbone Type Suspension)
HINT:
- Removal for 4WD
- Removal for 2WD

14. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY (for Double Wishbone Type Suspension)
HINT: Removal

15. DISCONNECT FUEL TANK VENT HOSE (for Torsion Beam Type Suspension)





(a) Disconnect the fuel tank vent hose.
(1) Pinch the tabs of the retainer of the fuel tube connector to disengage the lock claws and slide it as shown in the illustration.
(2) Pull the fuel tank vent hose out of the pipe.
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 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.

16. DISCONNECT BREATHER TUBE FUEL HOSE





(a) Disconnect the breather tube fuel hose.
(1) Remove the checker of the fuel tube connector from the pipe.
(2) Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
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 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 on the connector to release it. Pull the connector off the pipe carefully.





(b) Separate the breather tube fuel hose.
17. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Disconnect the fuel tank main tube.
(1) Pinch the tabs of the retainer of the fuel tube connector to disengage the lock claws and push it down as shown in the illustration.
(2) Pull the fuel tank main tube out of the pipe.
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 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 on the connector to release it. Pull the connector off the pipe carefully.

18. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY





(a) Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.





(b) Loosen the hose clamp bolt, then disconnect the fuel tank filler pipe hose from the fuel tank.
19. REMOVE FUEL TANK ASSEMBLY (for 4WD)





(a) Hold the fuel tank using a transmission jack.





(b) Remove the 4 bolts, then remove the 2 No. 1 fuel tank bands.
(c) Operate the transmission jack, then remove the fuel tank.
20. REMOVE FUEL TANK ASSEMBLY (for 2WD)





(a) Hold the fuel tank using a transmission jack.





(b) Remove the 4 bolts, then remove the 2 No. 1 fuel tank bands.
(c) Operate the transmission jack, then remove the fuel tank.
21. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Remove the fuel tank main tube from the fuel tank.
22. REMOVE FUEL TANK VENT HOSE (for 4WD)





(a) Remove the fuel tank vent hose.
23. REMOVE FUEL TANK VENT HOSE (for 2WD)





(a) Remove the fuel tank vent hose from the fuel tank clamp.
24. REMOVE NO. 1 FUEL TANK CUSHION (for 4WD)





(a) Remove the No. 1 fuel tank cushions from the fuel tank.
25. REMOVE NO. 3 FUEL TANK CUSHION (for 4WD)





(a) Remove the No. 3 fuel tank cushions from the fuel tank.
26. REMOVE FUEL TANK CUSHION (for 2WD)





(a) Remove the fuel tank cushions from the fuel tank.