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Fuel Tank ASSY: Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION   ) 
  2. 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.
  3. DRAIN FUEL 
  4. REMOVE REAR SEAT CUSHION ASSY (See  OVERHAUL  ) 
  5. REMOVE REAR FLOOR SERVICE HOLE COVER NO. 2 
    1. Remove the 3 cap nuts and service hole cover.
    Fig 1: Removing Rear Floor Service Hole Cover No. 2
    G02958629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL PUMP TUBE SUB-ASSY 
    NOTE:
    • These procedures should be performed with the fuel tank less than 1/4 full.
    • Check for dirt and foreign matter 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 in these procedures.
    • Do not forcefully bend or twist the nylon tube.
    • Check for dirt and foreign matter on the pipe seal surface. Clean if necessary.
    • Put the pipe and connector ends in plastic bags to prevent damage and dirt and foreign matter.
    • If the pipe and connector are stuck together, pinch the tube and turn it carefully to free it. Then disconnect the tube.
    1. Disconnect the fuel tank side connector.
      1. Remove the tube joint clip.
      2. Pull out the fuel pump tube.
      3. Plug the port of the fuel suction plate with a clean rubber cap.
        Fig 2: Disconnecting Fuel Tank Side Connector
        G02958630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel pipe side connector.
      1. Clean the pipe.
      2. Hold the claw of the retainer with your thumb and pull out the connector.
      Fig 3: Disconnecting Fuel Pipe Side Connector
      G02958631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the connector and pipe are stuck together, release them by pushing and pulling them with hands.
      • Do not reuse the retainer.
    3. Protect each connecting part from damage and dirt by covering it with a plastic bag.
  7. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the fuel sender gauge connector.
  8. REMOVE FRONT FLOOR BRACE CENTER (See  OVERHAUL  ) 
  9. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER RH (See  OVERHAUL  ) 
  10. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER LH (See  OVERHAUL  ) 
  11. REMOVE ENGINE UNDER COVER 
  12. REMOVE EXHAUST PIPE ASSY (See  REPLACEMENT  ) 
  13. REMOVE FRONT FLOOR HEAT INSULATOR NO. 1 
    1. Remove the 4 bolts and heat insulator.
  14. REMOVE PROPELLER SHAFT ASSY (See  OVERHAUL  ) 
  15. REMOVE PARKING BRAKE CABLE ASSY NO. 2 (See  REPLACEMENT  ) 
  16. REMOVE PARKING BRAKE CABLE ASSY NO. 3 (See  REPLACEMENT  ) 
  17. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
  18. DISCONNECT BREATHER TUBE FUEL HOSE 
  19. DISCONNECT FUEL HOSE SUB-ASSY NO. 3 
  20. DISCONNECT FUEL TANK VENT HOSE 
  21. DISCONNECT FUEL CUT OFF W/TUBE VALVE ASSY 
  22. REMOVE FUEL TANK ASSY 
    1. Using a mission jack, support the fuel tank.
    2. Disconnect the fuel tank band and remove the fuel tank.
  23. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and set plate.
  24. REMOVE FUEL PUMP AND SENDER GAUGE ASSY 
    1. Lift up the fuel pump and sender gauge, and disconnect the fuel sub-suction hose from the fuel return jet tube. Then remove the fuel pump, sender gauge and gasket.
      Fig 4: Disconnecting Fuel Sub-Suction Hose From Fuel Return Jet Tube
      G02958632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Be careful not to damage the fuel pump filter.
    • Be careful not to bend the sender gauge arm.
  25. REMOVE FUEL SENDER GAUGE ASSY 
    1. Remove the 5 screws, sender gauge and gasket.
  26. REMOVE FUEL CUT OFF W/ TUBE VALVE ASSY 
    1. Remove the valve and gasket.
  27. REMOVE FUEL TANK PROTECTOR SUB-ASSY NO. 1 
  28. REMOVE FUEL TANK CUSHION NO. 1 
  29. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY 
    NOTE:
    • When installing or removing the check valve, do not use force. The check valve is made of resin and damages easily. Following these procedures carefully ensures that the check valve stays in good condition and maintains its sealing properties.
    • Check if the valves and gaskets must be replaced with new ones.
    1. Insert a clip remover between the check valve and the gasket, and remove the check valve by prying up the valve gradually.
      2. Fig 5: Removing Fuel Tank Over Fill Check Valve Assy
      G02958633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY 
    1. Install a new gasket to the fuel tank.
    2. Apply some gasoline to the entire circumference of a new over fill check valve, and insert it into the fuel tank.
    NOTE:
    • Do not insert the check valve with excessive force.
    • Be careful not to drop the gasket into the tank.
    • Make sure that there is no clearance between the gasket and the lower surface of the check valve.
  31. INSTALL FUEL TANK CUSHION NO. 1 
    1. Attach the fuel tank cushions to the shaded areas in Fig 6.
      Fig 6: Attaching Fuel Tank Cushions To Shaded Areas
      G02958634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL FUEL TANK PROTECTOR SUB-ASSY NO. 1 
  33. INSTALL FUEL CUT OFF W/ TUBE VALVE ASSY 
    1. Install a new gasket and the valve.
  34. INSTALL FUEL SENDER GAUGE ASSY 
    1. Install a new gasket and the sender gauge with the 5 screws.

      Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf) 

  35. INSTALL FUEL PUMP AND SENDER GAUGE ASSY 
    1. Install a new gasket to the fuel suction plate.
    2. Connect the fuel sub-suction hose to the fuel return jet tube.
    3. Attach the fuel pump and sender gauge to the fuel tank.
      Fig 7: Installing Fuel Pump & Sender Gauge Assy
      G02958635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the set plate with the 8 bolts.

      Torque: 6.0 N.m (61 kgf.cm, 52 in.lbf) 

  37. INSTALL FUEL TANK ASSY 
    1. Securely place a mission jack under the fuel tank.
    2. Jack up the fuel tank.
    3. Install the fuel tank and fuel tank band with the 4 bolts.

      Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 

  38. CONNECT FUEL CUT OFF W/ TUBE VALVE ASSY 
  39. CONNECT FUEL TANK VENT HOSE 
  40. CONNECT FUEL HOSE SUB-ASSY NO. 3 
  41. CONNECT BREATHER TUBE FUEL HOSE 
  42. CONNECT FUEL TANK TO FILLER PIPE HOSE 
  43. INSTALL PARKING BRAKE CABLE ASSY NO. 3 (See  REPLACEMENT  ) 
  44. INSTALL PARKING BRAKE CABLE ASSY NO. 2 (See  REPLACEMENT  ) 
  45. INSTALL PROPELLER SHAFT ASSY (See  OVERHAUL  ) 
  46. INSTALL FRONT FLOOR HEAT INSULATOR NO. 1 
    1. Install the heat insulator with the 4 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  47. INSTALL EXHAUST PIPE ASSY (See  REPLACEMENT  ) 
  48. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH (See  OVERHAUL  ) 
  49. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER RH (See  OVERHAUL  ) 
  50. INSTALL FRONT FLOOR BRACE CENTER (See  OVERHAUL  ) 
  51. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel sender gauge connector and install the service hole cover.
  52. INSTALL FUEL PUMP TUBE SUB-ASSY 
    1. Connect the connector on the fuel tank side.
      1. Attach the fuel tube connector to the fuel suction plate port.
      2. Install the tube joint clip.
    2. Connect the connector on the fuel pipe side.
      1. Insert the connector by aligning the pipe and the connector until the retainer makes a "click" sound.
      NOTE:
      • Check for damage and foreign matter in the pipe and around the connector.
      • After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.
      Fig 8: Installing Fuel Pump Tube Sub-Assy
      G02958636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL REAR FLOOR SERVICE HOLE COVER NO. 2 
    1. Install the service hole cover with the 3 nuts.
      Fig 9: Installing Rear Floor Service Hole Cover No. 2
      G02958637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL REAR SEAT CUSHION ASSY (See  OVERHAUL  ) 
  55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  56. PERFORM INITIALIZATION (See  INITIALIZATION  ) 
    NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  57. ADD FUEL 
  58. CHECK FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See  PRECAUTION   ) 
  59. CHECK FOR EXHAUST GAS LEAKS 
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