Removal

1NZ-FXE FUEL: FUEL TANK: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal
2. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER Removal
3. REMOVE FRONT FLOOR PANEL BRACE Removal
4. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal
5. REMOVE REAR SEAT CUSHION ASSEMBLY Removal
6. REMOVE REAR FLOOR SERVICE HOLE COVER





(a) Remove the butyl tape and rear floor service hole cover.
(b) Disconnect the fuel pump connector.
(c) Disconnect the wire to wire connector.
7. REMOVE FUEL TANK ASSEMBLY





(a) Disconnect the fuel tank from the canister tube.
(1) Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tank to canister tube from the pipe.
NOTICE:
- Remove dirt or foreign objects on the fuel tube connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank from the canister tube.
- If the fuel tube connector and pipe are stuck, push and pull them to release them.





(b) Disconnect the No. 2 fuel tank main tube.
(1) Remove the checker of the fuel tube connector from the pipe.
(2) Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe.
NOTICE:
- Remove dirt or foreign objects on the fuel tube connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-rings that seal the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the No. 2 fuel tank main tube.
- If the fuel tube connector and pipe are stuck, push and pull them to release them.





(c) Disconnect the fuel tank vent hose.
(1) Pinch the retainer and pull out the fuel tank vent hose connector with the fuel tank vent hose connector pushed to the pipe side to disconnect the fuel tank vent hose from the canister filter.
NOTICE:
- Remove dirt or foreign objects on the fuel tank vent hose connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank vent hose connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent hose connector and pipe are stuck, push and pull them to release them.





(d) Disconnect the fuel suction tube.
(1) Pinch the retainer and pull out the suction tube connector with the suction tube connector pushed to the pipe side to disconnect the fuel suction tube from the fuel tank to filler pipe.
NOTICE:
- Remove dirt or foreign objects on the quick connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel suction tube connector has the O-rings that seal the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the fuel suction tube.
- If the fuel suction tube connector and pipe are stuck, push and pull them to release them.





(e) Disconnect the No. 1 canister tube.
(1) Pinch the retainer and pull out the No. 1 canister tube connector with the No. 1 canister tube connector pushed to the pipe side to disconnect the No. 1 canister tube from the fuel tank to filler pipe.
NOTICE:
- Remove dirt or foreign objects on the quick connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the No. 1 canister tube connector has the O-rings that seal the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the tank to canister tube.
- If the No. 1 canister tube connector and pipe are stuck, push and pull them to release them.





(f) Set a transmission jack to the fuel tank.
(g) Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
(h) Remove the 4 bolts and No. 1 fuel tank band RH and LH.
(i) Operate the transmission jack, and then disconnect the fuel tank inlet pipe.
(j) Operate the transmission jack, and then remove the fuel tank.
8. REMOVE NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Remove the 3 nuts and rear fuel tank bracket.
(b) Disconnect the wire to wire connector from the rear fuel tank bracket.





(c) Disconnect the No. 2 fuel tank main tube from the clamp.
(d) Remove the checker of the main tube connector from the pipe.
(e) Pinch the retainer of the main tube connector, then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe.
NOTICE:
- Remove dirt or foreign objects on the fuel tube connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-rings that seal the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the No. 2 fuel tank main tube.
- If the fuel tube connector and pipe are stuck, push and pull them to release them.

9. REMOVE FUEL SUCTION TUBE SUB-ASSEMBLY





(a) Disconnect the fuel suction tube from the 2 No. 1 fuel tube clamps.
(b) Pinch the retainer and pull out the suction tube connector with the quick connector pushed to the pipe side to disconnect the fuel suction tube from the pipe.
NOTICE:
- Remove dirt or foreign objects on the quick connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the suction tube connector has the O-rings that seal the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the fuel suction tube.
- If the quick connector and pipe are stuck, push and pull them to release them.

10. REMOVE FUEL TANK TO CANISTER TUBE





(a) Disconnect the fuel tank to canister tube from the clamp.
(b) Disconnect the fuel tank to canister tube from the 2 No. 1 fuel tube clamps.
(c) Remove the fuel tank to canister tube from the fuel tank.
11. REMOVE TRAP CANISTER WITH PUMP MODULE





(a) Disconnect the VSV connector.
(b) Remove the clamp from the fuel tank vent hose and canister hose.
(c) Remove the fuel tank vent hose from the 2 fuel tube clamps.
(d) Remove the 2 bolts and trap canister with pump module and disconnect the ground terminal of the fuel tank wire.





(e) Remove the gasket from the fuel tank.





(f) Remove the 2 clamps from the trap canister with pump module.
12. REMOVE FUEL TANK VENT HOSE





(a) Pinch the retainer and pull out the fuel tank vent hose connector with the fuel tank vent hose connector pushed to the fuel tank vent hose side to disconnect the fuel tank vent hose from the trap with outlet valve canister.
NOTICE:
- Remove dirt or foreign objects on the fuel tank vent hose connector before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank vent hose connector has the O-ring that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, kink or twist the nylon tube.
- Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
- If the fuel tank vent hose connector and pipe are stuck, push and pull them to release them.





13. REMOVE FUEL TANK WIRE
(a) Remove the clamp as shown in the illustration A.
(b) Disconnect the VSV connector as shown in the illustration B.
(c) Disconnect the vapor pressure sensor connector as shown in the illustration C.
(d) Remove the 3 wire harness clamps as shown in the illustration D.
14. REMOVE CANISTER





(a) Disconnect the canister hose from the fuel tank retainer.
(b) Disconnect the No. 1 canister outlet hose from the fuel tank.
(c) Remove the bolt, 2 nuts and canister.





(d) Remove the nut from the fuel tank.
15. REMOVE FUEL TANK PRESSURE SENSOR





(a) Remove the tube joint clip, then pull out the fuel tank pressure sensor from the fuel tank retainer LH.
NOTICE:
- Remove dirt or foreign objects on fuel tank pressure sensor before this procedure.
- Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank pressure sensor has the O-ring that seals the plug.
- Perform this work by hand. Do not use any tools.

16. REMOVE FUEL TANK RETAINER LH





(a) Insert a clip remover between the fuel tank retainer and gasket, then remove the fuel tank retainer by lifting it little by little.
NOTICE:
- The fuel tank retainer is made of resin and easily damaged if removed or installed forcibly. Handle the part correctly to ensure proper sealing.
- After removing the fuel tank retainer, check that the contact surface of the fuel tank retainer on the fuel tank is not damaged.





(b) Remove the gasket from the fuel tank.





17. REMOVE NO. 1 FUEL TUBE CLAMP
(a) Remove the 2 clamps from the fuel tank.





18. REMOVE NO. 1 FUEL TANK CUSHION
(a) Remove the 9 cushions from the fuel tank.