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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL   ) 
  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. REMOVE SERVICE PLUG GRIP  (See REMOVAL )
  4. REMOVE REAR SEAT CUSHION ASSEMBLY  (See REMOVAL )
  5. REMOVE ROOM NO. 3 PARTITION PAD 
    1. Remove the clip and room partition pad.
      Fig 1: Identifying Partition Pad With Clip
      G05287239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the 2 connectors.
      Fig 2: Locating Rear Floor No. 2 Service Hole Cover
      G05303280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Disconnect the fuel main tubes and fuel return vent tube.
      1. Remove the 2 tube joint clips and fuel tubes.
        NOTE:
        • 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.
          Fig 3: Identifying Tube Joint Clips And Fuel Tubes
          G05303281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts and set plate.
      Fig 4: Locating Bolts And Set Plate
      G05303282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel tube.
    4. Remove the fuel suction tube with pump and gauge from the fuel tank.
      NOTE:
      • Make sure that the sender gauge arm does not bend.
      • Do not damage the fuel suction tube with pump and gauge.
        Fig 5: Connecting Fuel Hose With Clip
        G05303283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the fuel sender gauge connector.
      Fig 6: Locating Rear Floor Service Hole Cover
      G05303284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Remove the 5 screws and fuel sender gauge.
      Fig 7: Locating Fuel Sender Gauge Assembly
      G05303285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE EXHAUST PIPE ASSEMBLY 
    1. Remove the exhaust pipe (see REMOVAL ).
  11. REMOVE FRONT FLOOR COVER CENTER RH 
    1. Remove the 3 nuts, 2 clips and floor cover.
      Fig 8: Locating Floor Cover, Clips And Nuts (RH)
      G05303286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT FLOOR COVER CENTER LH 
    1. Remove the 3 nuts, 2 clips and floor cover.
      Fig 9: Locating Floor Cover, Clips And Nuts (LH)
      G05303287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR 
    1. Remove the 5 nuts and heat insulator.
      Fig 10: Locating Heat Insulator And Nuts
      G05303288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE OUTSIDE AIR GUIDE PLATE RH 
    1. Remove the 4 nuts and plate.
      Fig 11: Locating Outside Air Guide Plate RH With 4 Nuts
      G05295991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY  (See REMOVAL )
  16. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Remove the 2 nuts and differential support protector.
      Fig 12: Locating Differential Supporter With Nuts
      G05287075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Remove the 2 nuts and differential support protector.
  18. REMOVE REAR FLOOR SIDE MEMBER COVER LH 
    1. Remove the 3 bolts and member cover.
      Fig 13: Locating Bolts And Member Cover (LH)
      G05303291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE REAR FLOOR SIDE MEMBER COVER RH 
    1. Remove the 3 bolts and member cover.
      Fig 14: Locating Bolts And Member Cover (RH)
      G05303292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE REAR SUSPENSION MEMBER BRACE LH 
    1. Remove the 4 bolts and suspension member brace.
      Fig 15: Locating Suspension Member Brace And Bolts (LH)
      G05303293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE REAR SUSPENSION MEMBER BRACE RH 
    1. Remove the 4 bolts and suspension member brace.
      Fig 16: Locating Suspension Member Brace And Bolts (RH)
      G05303294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Detach the 2 parking brake cables from the 4 clamps.
    2. Remove the 4 bolts and disconnect the 2 parking brake cables from the parking brake equalizer.
      Fig 17: Locating Parking Brake Cables With Clamps
      G05303295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT FUEL TANK RETURN VENT TUBE 
    1. Disconnect the fuel tank return vent tube.
      NOTE:
      • 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.
        Fig 18: Locating Fuel Tank Return Vent Tube
        G05303296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube RH.
      NOTE:
      • 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 forcefully bend or twist the nylon tube.
      • Check for any 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 contamination.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
        Fig 19: Locating Fuel Tank Main Tube RH
        G05303297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank main tube LH.
      NOTE:
      • 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 forcefully bend or twist the nylon tube.
      • Check for any 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 contamination.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
        Fig 20: Locating Fuel Tank Main Tube LH
        G05303298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Remove the clamp and disconnect the vent hose.
      NOTE:
      • 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.
        Fig 21: Locating Vent Hose And Clamp
        G05303299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Remove the fuel tube clamp and disconnect the canister tube.
      NOTE:
      • 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.
        Fig 22: Locating Fuel Tube Clamp And Canister Tube
        G05303300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT FUEL TANK WIRE 
    1. Disconnect the fuel vapor containment valve connector and 2 clamps.
      Fig 23: Locating Fuel Vapor Containment Valve Connector And Clamps
      G05303301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FUEL TANK SUB-ASSEMBLY 
    1. Loosen the 2 fuel filler pipe bolts.
      Fig 24: Locating Fuel Filler Pipe Bolts
      G05303302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place a mission jack under the fuel tank.
    3. Remove the 4 bolts and 2 fuel tank bands.
    4. Slowly lower the mission jack slightly.
      NOTE: Make sure that no load is applied to the fuel filler pipe.
      Fig 25: Locating Fuel Tank Bands And Bolts
      G05303303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the clamp, disconnect the fuel filler pipe from the fuel tank, and lower the mission jack.
      Fig 26: Identifying Fuel Filler Pipe And Fuel Tank
      G05303304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 3 FUEL TANK PROTECTOR  (See REMOVAL )
  30. REMOVE FUEL PRESSURE SENSOR  (See REMOVAL )
  31. REMOVE FUEL TANK VENT TUBE SET PLATE  (See REMOVAL )
  32. REMOVE FUEL TANK WIRE 
    1. Remove the 7 clamps and tank wire from the tank.
      Fig 27: Locating Clamps And Tank Wire Tank
      G05303305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Remove the 4 screws, gasket and canister tube.
      Fig 28: Locating Fuel Tank To Canister Tube Sub-Assembly
      G05303306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the clamp, fuel tank main tube and return tube.
      Fig 29: Locating Fuel Tank Main Tube And Return Tube
      G05303307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 2 claws and remove the edge protector.
      Fig 30: Removing Edge Protector
      G05303308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Remove the vent hose from the fuel tank.
      NOTE:
      • 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.
        Fig 31: Identifying Vent Hose To Fuel Tank
        G05303309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FUEL TANK CUSHION 
    1. Remove the 11 tank cushions.
      Fig 32: Identifying Tank Cushions
      G05303310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the tank protector and tank cushion.
      Fig 33: Identifying Tank Protector And Tank Cushion
      G05303311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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