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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See PRECAUTION  .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE REAR SEAT CUSHION ASSEMBLY  (See REMOVAL )
  4. REMOVE REAR FLOOR SERVICE HOLE COVER (See  REMOVAL   ) 
  5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See  REMOVAL   ) 
  6. REMOVE FUEL TANK VENT TUBE SET PLATE (See  REMOVAL   ) 
  7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See  REMOVAL   ) 
  8. DRAIN FUEL 
  9. REMOVE CENTER EXHAUST PIPE ASSEMBLY 

    See REMOVAL

  10. REMOVE FRONT FLOOR BRACE RH 
    1. Remove the bolt and 2 nuts, and remove the front floor brace RH.
      Fig 1: Locating Front Floor Brace Bolts And Nuts RH
      G05248548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT FLOOR BRACE LH 
    1. Remove the bolt and 2 nuts, and remove the front floor brace LH.
      Fig 2: Locating Front Floor Brace LH Bolts And Nuts
      G05248549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the set bolt and set nut of the No. 2 parking brake cable assembly.
      Fig 3: Locating Set Bolt And Set Nut Of No. 2 Parking Brake Cable Assembly
      G05248550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the set bolt and set nut of the No. 3 parking brake cable assembly.
      Fig 4: Identifying Set Bolt And Set Nut Of No. 3 Parking Brake Cable Assembly
      G04974954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET 
    1. Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets.
      Fig 5: Locating Rear Stabilizer Bar No. 1 Brackets Bolts
      G05248552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK PROTECTOR LOWER CENTER 
    1. Remove the 4 bolts and 2 clips.
    2. Remove the fuel tank protector.
      Fig 6: Identifying Bolts And Clips (For Se Grade)
      G04974957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel pump tube.
      1. Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.
      2. Pull out the fuel tank main tube.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
        • It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.
          Fig 7: Pinching Tab Of Retainer To Disengage Lock Claws
          G04974958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the No. 1 fuel tube.
      1. Pinch the tube connector and then pull out the No. 1 fuel tube.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
        • It is necessary to prevent mud or dirt from entering the quick connector, if mud or dirt gets in the connector, the O-rings may not seal properly.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.
          Fig 8: Pulling Out Fuel Tube No.1
          G04974959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place a transmission jack under the fuel tank assembly.
      Fig 9: Placing Transmission Jack Under Fuel Tank Assembly
      G04974960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 set bolts of the fuel tank bands. (*1)
    5. Remove the hose clamp and disconnect the fuel tank to filter pipe hose. (*2)
    6. Slightly lower the transmission jack.
    7. Disconnect the fuel tank vent hose from the charcoal canister. (*3)
      1. Push the connector deep into the charcoal canister to release the locking pin.
      2. Pinch portion A.
      3. Pull out the connector.
    8. Remove the fuel tank.
      Fig 10: Pinching Portion A
      G04974961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
      Fig 11: Removing Pins And Fuel Tank Bands
      G04974962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 4 clip nuts.
      Fig 12: Locating Clip Nuts (For Se Grade)
      G04974964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK VENT HOSE 
    1. Push the connector deep into the charcoal canister to release the locking pin.
    2. Pinch portion A.
    3. Pull out the connector.
      Fig 13: Pinching Portion A
      G04974965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Remove the fuel pump tube from the fuel main tube support.
      Fig 14: Locating Fuel Pump Tube
      G04974966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL MAIN TUBE SUPPORT 
    1. Remove the bolt and tube support.
      Fig 15: Locating Fuel Main Tube Support With Bolt
      G04974967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 2 FUEL TANK CUSHION 
    1. Remove the 7 No. 2 fuel tank cushions.
      Fig 16: Identifying No. 2 Fuel Tank Cushions
      G04974968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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