2NZ-FE FUEL  FUEL TANK  REMOVAL  


PROCEDURE

Hide 77020A 1.REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE FUEL>FUEL PUMP>REMOVAL

Hide 2.DRAIN FUEL

Hide 17410 3.REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

Click hereEngine / Hybrid System>2NZ-FE INTAKE / EXHAUST>EXHAUST PIPE>REMOVAL

Hide 77249 4.DISCONNECT FUEL EMISSION HOSE

a.
A310748

Disconnect the fuel emission hose from the fuel pipe.


Hide 77202A 5.DISCONNECT BREATHER TUBE FUEL HOSE

a.
A310749

Loosen the clamp, then disconnect the breather tube fuel hose from the fuel pipe.


Hide 75259A 6.DISCONNECT FUEL HOSE

NOTICE:

Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


a.
A321321C01
0.573,0.292 1.542,0.292 1.542,0.292 1.542,0.552 false 0.906,0.563 0.906,0.292 false 0.74,1.406 0.885,1.406 0.885,1.406 0.99,1.167 false 1.354,4.396 1.583,4.396 1.583,4.396 1.583,4.042 false 1.802,4.24 1.802,4.448 1.802,4.448 2.073,4.448 false 1.875,3.615 2.01,3.24 2.01,3.24 2.125,3.24 false 2.188,3.802 2.365,3.385 2.365,3.385 2.469,3.385 false 2.167,3.146 2.479,3.302 0.313,0.156 10 false *a 2.125,4.365 2.438,4.521 0.313,0.156 10 false *b 1.208,4.302 1.521,4.458 0.313,0.156 10 false *c 2.552,3.302 2.865,3.458 0.313,0.156 10 false *d 0.417,0.188 0.729,0.344 0.313,0.156 10 false *e 0.573,1.313 0.885,1.469 0.313,0.156 10 false *a
*a Retainer
*b Fuel Tube Connector
*c O-ring
*d Fuel Pipe
*e Claw
V100135

Push
V100136

Pull out
V100137

Pull off


Disconnect the fuel hose.

i.

Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

NOTICE:

Be sure to disconnect the fuel tube connector by hand.



ii.

If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

NOTICE:
·

Be sure to disconnect the fuel tube connector by hand.

·

Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the fuel pipe.




iii.

Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.


iv.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.



Hide 77209F 7.DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

NOTICE:

Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.


a.
A310288C01
1.771,2.844 1.917,2.844 1.917,2.844 2.021,2.646 false 2.271,3.208 2.375,3.208 2.375,3.208 2.479,3.469 false 2.635,3.531 2.833,3.083 2.833,3.083 2.927,3.083 false 2.073,4.365 2.073,3.948 false 1.76,4.365 2.229,4.365 2.229,4.365 2.229,3.938 false 2.958,4.271 2.958,4.125 2.958,4.125 2.677,3.885 false 1.604,2.75 1.917,2.906 0.313,0.156 10 false *a 1.583,4.271 1.896,4.427 0.313,0.156 10 false *b 2.115,3.115 2.427,3.271 0.313,0.156 10 false *c 2.885,4.281 3.198,4.438 0.313,0.156 10 false *d 2.969,3 3.281,3.156 0.313,0.156 10 false *a
*a Retainer
*b O-ring
*c Fuel Tube Connector
*d Fuel Pipe
V100135

Pull out
V100136

Pull off


Disconnect the fuel tank main tube sub-assembly.

i.

Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

NOTICE:

Be sure to disconnect the fuel tube connector by hand.



ii.

If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

NOTICE:
·

Be sure to disconnect the fuel tube connector by hand.

·

Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.




iii.

Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.


iv.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.



Hide 8.SEPARATE PARKING BRAKE CABLE ASSEMBLY

a.
A310753

Remove the 2 bolts and separate the No. 2 parking brake cable assembly.


b.
A310754

Remove the 2 bolts and separate the No. 3 parking brake cable assembly.


Hide 77213B 9.DISCONNECT FUEL TANK TO FILLER PIPE HOSE

a.
A315528

Using a screwdriver, disengage the claw. Then remove the fuel tank filler pipe protector from the fuel tank to filler pipe hose.


b.
A315529

Loosen the clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank sub-assembly.


Hide 77001A 10.REMOVE FUEL TANK SUB-ASSEMBLY

a.
A155342

Support the fuel tank sub-assembly using an engine lifter.

HINT:

Using height adjustment attachments and plate lift attachments, place the fuel tank sub-assembly horizontally.



b.
A155343

Remove the 4 bolts and fuel tank band sub-assembly LH.


c.

Lower the engine lifter to remove the fuel tank sub-assembly.

NOTICE:
·

Do not drop the fuel tank sub-assembly.

·

When removing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.




Hide 77209F 11.REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

a.
A310292

Disengage the 3 clamps to remove the fuel tank main tube sub-assembly from the 2 tank suction tube supports and fuel tube clamp.


Hide 75259A 12.REMOVE FUEL HOSE

a.
A310755

Disengage the 3 clamps to remove the fuel hose from the 2 tank suction tube supports and fuel tube clamp.


Hide 77158A 13.REMOVE TANK SUCTION TUBE SUPPORT

a.
A155341

Disengage the 2 claws to remove the 2 tank suction tube supports from the fuel tank sub-assembly.


Hide 77284 14.REMOVE FUEL TUBE CLAMP

a.
A155340

Disengage the 2 claws to remove the fuel tube clamp from the fuel tank sub-assembly.


Hide 77202A 15.REMOVE BREATHER TUBE FUEL HOSE

a.
A310756

Loosen the clamp, then remove the breather tube fuel hose from the fuel tank sub-assembly.


Hide 77249 16.REMOVE FUEL EMISSION HOSE

a.
A184615

Disengage the 2 claws to remove the fuel emission hose from the fuel tank sub-assembly.


Hide 77011 17.REMOVE LOWER FUEL TANK FILLER PIPE SUB-ASSEMBLY

a.
A169335

Remove the 5 bolts, lower fuel tank filler pipe sub-assembly and lower fuel tank filler pipe gasket from the fuel tank sub-assembly.


Hide 77651A 18.REMOVE NO. 1 FUEL TANK CUSHION

a.
A184616

Remove the 7 No. 1 fuel tank cushions from the fuel tank sub-assembly.


Hide 77641A 19.REMOVE NO. 1 FUEL TANK PROTECTOR

a.
A155344C01
2.646,1.458 2.646,1.073 false 2.583,1.469 2.896,1.625 0.313,0.156 10 false *a 2.719,0.354 3.031,0.51 0.313,0.156 10 false *b
*a Tape
*b 5.0 mm (0.197 in.)


Using a drill bit with a diameter of less than 4.0 mm (0.157 in.), drill out the 4 rivet flanges, push out the remaining rivet fragments and remove the No. 1 fuel tank protector and fuel tank band sub-assembly RH from the fuel tank sub-assembly.

CAUTION:

Perform this operation in a well-ventilated area.


NOTICE:
·

Securely hold the fuel tank sub-assembly.

·

Prying on the rivets with a drill can lead to damage to the rivet hole or the drill itself.

·

Be careful when performing this operation as the cut rivets will be hot.

·

Do not cut or enlarge the rivet holes.



HINT:

Wind tape around the drill bit approximately 5.0 mm (0.197 in.) from the tip as shown in the illustration.