Removal (from 07/2011)

1NZ-FE FUEL: FUEL TANK (for Hatchback): REMOVAL

1. PRECAUTION

(a) When removing and storing the fuel tank assembly, arrange the inlet hose as shown in the illustration, and secure the fuel tank assembly using a cord or similar.





Text in Illustration





NOTICE:
Depending on the arrangement of the inlet hose during storage, the inlet hose and rear suspension may interfere and cause fuel leakage.

2. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

Removal (from 07/2011)

3. DRAIN FUEL

4. REMOVE REAR CONSOLE BOX ASSEMBLY

Removal (from 07/2011)

5. REMOVE FRONT FLOOR CENTER BRACE Removal (from 07/2011)

6. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal (from 07/2011)

7. REMOVE EXHAUST PIPE GASKET Removal (from 07/2011)

8. REMOVE NO. 2 EXHAUST PIPE GASKET Removal (from 07/2011)

9. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR

(a) Remove the 2 nuts and the front No. 4 floor heat insulator.





10. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY

(a) Pinch and remove the clip as shown in the illustration.





(b) Remove the bolt and the fuel tank cover vent case sub-assembly.

11. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

NOTICE:
Before disconnecting the fuel tube connector, check for dirt or other foreign matter on the fuel tube connector and the pipe, and clean them if necessary.

(a) Disengage the fuel tube connector cover.





Text in Illustration





(b) Pinch the retainer by hand from both sides, and pull out the fuel tube connector from the pipe.

NOTICE:
* If the fuel tube connector and pipe are stuck together, push in and pull out the fuel tube connector while squeezing the pipe to release the connection, and then disconnect the fuel tube connector.
* Clean away any dirt or foreign matter from the fuel tube connector before performing the operation.
* The fuel tube connector and pipe are sealed by O-rings, so be careful to prevent damage to and foreign matter sticking to the contact surfaces.
* Do not use any tools.
* After disconnecting the fuel tube connector, check that there is no foreign matter on the seal surface of the pipe.
* After disconnecting the fuel tube, protect the contact surfaces by covering them with a plastic bag.
* Do not bend or twist the tubes.

12. DISCONNECT FUEL TANK VENT HOSE

NOTICE:
Before disconnecting the fuel tank vent hose sub-assembly, check for dirt or other foreign matter on the fuel tank vent hose sub-assembly and the charcoal canister assembly, and clean them if necessary.

(a) Release the retainer as shown in the illustration and disconnect the fuel tank vent hose sub-assembly.





Text in Illustration





13. REMOVE FUEL TANK ASSEMBLY





(a) Remove the bolt, disengage the claw and separate the fuel tank filler pipe assembly.

(b) Using an engine lifter, support the fuel tank assembly.

(c) Remove the bolt and separate the parking brake cable.





(d) Remove the 4 bolts and fuel tank assembly.





NOTICE:
Make sure that the fuel tank does not fall.

14. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the fuel tank main tube from the fuel tank assembly.





15. REMOVE FUEL TANK VENT HOSE

(a) Remove the fuel tank vent hose sub-assembly from the fuel tank assembly.





16. REMOVE FUEL TANK FILLER PIPE PROTECTOR





(a) Remove the clip from the fuel tank filler pipe protector.

(b) Disengage the 2 claws and remove the No. 2 fuel tube support protector.

(c) Disengage the 2 claws and remove the fuel tank filler pipe protector.

17. REMOVE BREATHER TUBE CLAMP

(a) Disengage the claw and clamp as shown in the illustration, and remove the breather tube clamp.