FUEL TANK (except Regular Cab Short Deck) REMOVAL


  1. 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.

  2. LOOSEN FUEL TANK CAP

  3. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. Remove the 4 nuts and fuel tank protector.

  4. DISCONNECT FUEL MAIN TUBE AND FUEL RETURN TUBE


    1. Move the 2 clamps to remove the 2 tubes.

      Note


      • To protect the tube, cover it with a plastic bag after checking it.

      • If the tube and pipe are stuck, turn the tube carefully to free it and then disconnect the fuel tank tube.

  5. DISCONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01E1UBE01

      Disconnect the filler pipe hose from the fuel tank filler pipe.

  6. DISCONNECT FUEL TANK BREATHER HOSE


    1. Disconnect the breather hose from the fuel tank filler pipe.

  7. REMOVE FUEL TANK FILLER PIPE


    1. Remove the bolt and filler pipe.

  8. REMOVE FUEL TANK


    1. A01E17OE01

      Set a mission jack to the fuel tank.

    2. Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.

    3. Slightly lower the mission jack.

      Note

      Be careful not to cut the wirings.

    4. A01DZHSE01

      Remove the clip. Then fold back approximately half of each cushion rubber so that the wire harness can be removed in the next step.

    5. A01DWSGE01

      Disconnect the fuel pump connector and detach the 6 wire harness clips from the fuel tank.

      Note


      • Before this procedure, check the connector for dirt, mud or other contamination.

      • Do not use any tools in this procedure.

  9. REMOVE NO. 1 FUEL TANK CUSHION


    1. Remove the nut.

    2. A01E302E03

      Using needle-nose pliers, remove the 4 clips and nut as shown in the illustration and then remove the heat insulator.

    3. A01DXWGE01

      Remove the clip and 2 fuel tank cushions from the fuel tank.

  10. REMOVE FUEL PUMP GAUGE RETAINER


    1. A01E2RBE01

      Remove the 2 tube joint clips and pull out the 2 fuel tank tubes.

      Note

      A01E1OPE17

      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.

      • 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 step by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      • Protect the disconnected parts by covering them with plastic bags and tape after disconnecting the fuel tubes.

    2. Remove the fuel tank return tube and fuel tank main tube from the fuel tank.

    3. A01DZK5E04

      Temporarily install SST (plate and 4 claws) to the fuel pump gauge retainer.

      SST
      09808-14030

      Tech Tips


      • Be sure to use 4 SST (claws) as shown in the illustration.

      • Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.

    4. While pressing SST (claws) to the fuel pump gauge retainer ribs securely, install the 4 bolts.

      Tech Tips

      Install SST while pressing SST (claws) against the fuel pump gauge retainer (towards the center of SST).

    5. Install SST (handle).

    6. A01E18CE03

      Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to loosen the fuel pump gauge retainer.

      SST
      09808-14030

      Note


      • When the retainer is loosened, be careful as the fuel pump will spring upward from the force of the spring.

      • Clean the fuel tank vent tube before this operation.

      • Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.

      • Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

      • Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.

      • Do not spin SST too fast or use an impact wrench as this may result in damage to components.

      • If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.

      Tech Tips

      The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.

    7. Remove the fuel pump gauge retainer.

  11. REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. Remove the fuel tank vent tube from the fuel tank.

      Note

      Be careful not to bend the arm of the fuel sender gauge.

    2. Remove the gasket from the fuel tank.