Removal

1UR-FSE FUEL: FUEL TANK: REMOVAL

REMOVAL

1. PRECAUTION Removal

2. DISCHARGE FUEL SYSTEM PRESSURE
(a) Discharge fuel system pressure Service Precautions.
3. REMOVE COWL TOP VENTILATOR LOUVER RH Removal

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

5. REMOVE REAR SEAT ASSEMBLY (for Power Seat)
(a) Remove the rear seat assembly Removal.
6. REMOVE REAR SEAT ASSEMBLY (for Ottoman)
(a) Remove the rear seat assembly Removal.
7. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type)
(a) Remove the rear seat cushion assembly Removal.
8. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER

(a) Remove the service hole cover and disconnect the connector from the fuel suction with pump and gauge tube assembly.

9. REMOVE FUEL TANK MAIN AND RETURN TUBE
(a) Disconnect the fuel main tube and fuel return tube.
(1) Remove the 2 tube joint clips and 2 fuel tubes.
NOTICE:
- Remove any dirt and foreign matter on the fuel tube joint before performing this work.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.

10. REMOVE REAR FLOOR SERVICE HOLE COVER

(a) Remove the service hole cover and disconnect the fuel sender gauge connector.
11. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Remove the exhaust pipe Removal.
12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
(a) Remove the propeller with center bearing shaft Removal.
13. REMOVE FUEL TANK ASSEMBLY

(a) Disconnect the fuel main tube.
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.

(b) Disconnect the fuel return tube.
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel return tube.
- If the pipe and connector are stuck together, pinch the vent tube between your fingers and turn it carefully to free it. Then disconnect the fuel return tube.

(d) Place a mission jack under the fuel tank.
(e) Remove the 4 bolts and 2 fuel tank bands.
(f) Lower the mission jack so that the fuel tank breather tube can be disconnected.
NOTE: Make sure that no load is applied to the fuel filler pipe.
HINT: Lower the mission jack slowly.

(g) Disconnect the fuel tank breather tube sub-assembly.
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the breather tube.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the breather tube.

(h) Disconnect the fuel tank vent hose sub-assembly.
(1) Pinch the retainer and then raise it.
NOTICE:
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the vent hose contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the vent hose.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.

(i) Lower the mission jack to remove the fuel tank from the vehicle.
NOTICE:
- Do not allow the fuel tank to contact the vehicle, especially the differential.
- Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.
HINT: Lower the mission jack slowly.

14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

(a) Remove the 8 bolts and fuel vent tube set plate.

(b) Disconnect the fuel hose.
(c) Remove the fuel suction with pump and gauge tube from the fuel tank.
NOTICE:
- Make sure that the sender gauge arm does not bend.
- Do not damage the fuel suction tube with pump and gauge.

(d) Remove the gasket.
15. REMOVE FUEL SENDER GAUGE ASSEMBLY

(a) Remove the 5 screws and fuel sender gauge.
(b) Remove the gasket.
16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Remove the 6 clamps and fuel tank main tube from the fuel tank.

(b) Remove the fuel hose clamp.

17. REMOVE NO.2 FUEL TANK PROTECTOR
(a) Remove the bolt and clip and fuel tank protector from the fuel tank.
(b) Remove the clamp from the fuel tank.
18. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Disconnect the fuel tank vent hose sub-assembly.
- Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
- Do not use any tools to separate the pipe and connector.
- Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
- Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the vent hose.
- If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.

19. REMOVE FUEL TANK CUSHION

(a) Remove the 3 tank cushions.

(b) Remove the tank protector and 5 tank cushions.