Removal

1NR-FE FUEL: FUEL TANK: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Fuel System: Precaution

2. SEPARATE FUEL TANK WIRE

(a) Peel back the floor carpet under the front left seat, disconnect the fuel tank wire connector, and pass the grommet through the floor.

3. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Remove the 2 clips and 4 nuts.

(b) Disengage the claw and remove the No. 1 fuel tank protector.

4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Release the checker as shown in the illustration.

Text in Illustration

(b) Pinch the retainer to release it as shown in the illustration and disconnect the fuel tank main tube.

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The quick connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

5. DRAIN FUEL

(a) Drain the fuel from the inlet tube installation position.

6. DISCONNECT FUEL TANK VENT HOSE

(a) Release the retainer as shown in the illustration and disconnect the fuel tank vent hose and disengage the clamp.

Text in Illustration

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The quick connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

7. REMOVE FUEL TANK FILLER PIPE PROTECTOR

(a) Disengage the claw and remove the fuel tank filler pipe protector.

8. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY

(a) Insert a screwdriver with its tip wrapped in protective tape into the quick connector cutout as shown in the illustration, push the quick connector lock forward, and disconnect the fuel tank filler pipe.

Text in Illustration

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The quick connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

9. REMOVE FUEL TANK ASSEMBLY

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

(b) Remove the 4 bolts and the 2 fuel tank bands.

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

10. REMOVE NO. 1 FUEL TANK PROTECTOR

(a) Remove the 3 nuts and the No. 1 fuel tank protector.

11. REMOVE FUEL TANK CUSHION

(a) Remove the No. 1 fuel tank cushions, No. 2 fuel tank cushions, No. 3 fuel tank cushions and the No. 4 fuel tank cushion.

Text in Illustration

12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Widen the tip of the tube joint clip and pull out the clip in the direction indicated by the arrow.

(b) Pull the fuel tank main tube off of the fuel suction tube to disconnect it.

Text in Illustration

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

(c) Disengage the clamp and remove the fuel tank main tube.

13. REMOVE FUEL TANK WIRE

(a) Disconnect the 2 fuel tank wire connectors from the fuel suction tube and fuel tank vent tube.

(b) Disengage the 7 clamps and remove the fuel tank wire.

(c) Remove the fuel hose clamp from the fuel tank wire.

14. REMOVE NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

(a) Release the retainer as shown in the illustration and disconnect the No. 1 fuel evaporation tube from the fuel suction tube and fuel tank vent tube assembly.

Text in Illustration

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

(b) Disengage the clamp and remove the No. 1 fuel evaporation tube.

15. REMOVE NO. 2 FUEL EVAPORATION TUBE SUB-ASSEMBLY

(a) Release the retainer as shown in the illustration and disconnect the No. 2 fuel evaporation tube from the fuel tank vent tube assembly.

Text in Illustration

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

(b) Disengage the clamp and remove the No. 2 fuel evaporation tube.

16. REMOVE FUEL TANK VENT HOSE

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

Text in Illustration

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The fuel tube connector seals with an O-ring.
Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

(b) Disengage the clamp and remove the fuel tank vent hose.

17. REMOVE FUEL PUMP GAUGE RETAINER

(a) Release the retainer as shown in the illustration and disconnect the fuel tank breather tube.

Text in Illustration

NOTICE:
* Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
* The fuel tube connector seals with an O-ring.
Ensure that there is no damage or foreign matter on the contact surface.
* Do not use any tools.
* Do not bend or twist the tubes.
* Protect the contact surface by covering it with a plastic bag.
* If the connector is stuck, push and pull on the parts to separate them.

(b) Set the plate and claws of SST onto the fuel pump gauge retainer and temporarily tighten the bolts.

SST : 09808-14030

09808-01030

09808-01040

09808-01050

(c) While firmly pressing the claws of SST against the ribs of the retainer, fully tighten each bolt.

(d) Set SST handle in place.

SST : 09808-14030

09808-01010

09808-01020

(e) While pressing down tightly on SST to prevent it from rising up, slowly rotate the handle to loosen the retainer.

NOTICE:
* Pressing the retainer against the pump with excessive force will make it difficult to turn and may damage the parts, so do not press down too strongly on SST.
* Applying excessive force at an angle may cause SST to slip off, so be sure to keep the handle level while rotating.
* To avoid damaging the parts, do not turn the handle of SST too forcefully, and do not use an impact wrench.
* If SST slips off the retainer, stop turning the handle, loosen the bolts of SST, and perform the SST set procedure again.

(f) Remove the fuel pump gauge retainer while holding the fuel tank vent tube assembly by hand.

18. REMOVE FUEL TANK VENT TUBE ASSEMBLY

NOTICE:
Do not disconnect the tube shown in the illustration.

(a) Rotate the fuel tank vent tube assembly toward the inside of the tank, and remove it in the opposite direction to the arrows for insertion of the fuel tank sender gauge.

Text in Illustration

NOTICE:
Do not bend the sender gauge arm.

(b) Disengage the 2 claws of the fuel tank vent tube assembly, disconnect the fuel tank vent tube sub-assembly, and remove the fuel tank vent tube assembly.

19. REMOVE FUEL TANK SUCTION TUBE GASKET

(a) Remove the gasket from the fuel tank.

20. REMOVE FUEL PUMP GAUGE RETAINER

(a) Set the plate and claws of SST onto the fuel pump gauge retainer and temporarily tighten the bolts.

SST : 09808-14030

09808-01030

09808-01040

09808-01050

(b) While firmly pressing the claws of SST against the ribs of the retainer, fully tighten each bolt.

(c) Set SST handle in place.

SST : 09808-14030

09808-01010

09808-01020

(d) While pressing down tightly on SST to prevent it from rising up, slowly rotate the handle to loosen the retainer.

NOTICE:
* Pressing the retainer against the pump with excessive force will make it difficult to turn and may damage the parts, so do not press down too strongly on SST.
* Applying excessive force at an angle may cause SST to slip off, so be sure to keep the handle level while rotating.
* To avoid damaging the parts, do not turn the handle of SST too forcefully, and do not use an impact wrench.
* If SST slips off the retainer, stop turning the handle, loosen the bolts of SST, and perform the SST set procedure again.

(e) Remove the fuel pump gauge retainer while holding the fuel suction tube by hand.

21. REMOVE FUEL SUCTION TUBE ASSEMBLY

NOTICE:
Do not disconnect the tube shown in the illustration.

(a) Pinch the fuel tank vent tube retainer to release it as shown in the illustration, disconnect the fuel tank vent tube sub-assembly, and then remove the fuel suction tube.

Text in Illustration

22. REMOVE FUEL TANK SUCTION TUBE GASKET

(a) Remove the gasket from the fuel tank.

23. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY

(a) Pull the fuel tank vent tube sub-assembly out of the fuel tank.

24. REMOVE NO. 1 EVAPORATION VENT TUBE CLAMP

(a) Disengage the claw and remove the No. 1 evaporation vent tube clamp.