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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See PRECAUTION  .

  2. REMOVE DECK BOARD SUB-ASSEMBLY  (See REMOVAL  ).
  3. REMOVE REAR SEAT ASSEMBLY RH 

    HINT:

    See REMOVAL .

  4. REMOVE REAR SEAT ASSEMBLY LH 

    HINT:

    See REMOVAL .

  5. REMOVE REAR DOOR SCUFF PLATE LH  (See REMOVAL )
  6. REMOVE DECK SIDE TRIM COVER LH  (See REMOVAL )
  7. REMOVE REAR SEAT SIDE COVER LH  (See REMOVAL )
  8. REMOVE REAR FLOOR SERVICE HOLE COVER  (See REMOVAL  )
  9. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE  (See REMOVAL  )
  10. DRAIN FUEL 
  11. REMOVE NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover) 
  12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)  (See REMOVAL )
  13. REMOVE EXHAUST CENTER PIPE ASSEMBLY 

    HINT:

    See REMOVAL .

  14. REMOVE NO. 3 FRONT FLOOR HEAT INSULATOR  (See REMOVAL )
  15. REMOVE NO. 4 EXHAUST PIPE SUPPORT BRACKET (for 4WD) 
    Fig 1: Identifying No. 4 Exhaust Pipe Support Bracket Bolts
    G05239100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 bolts, and then remove the No. 4 exhaust pipe support bracket.
  16. REMOVE NO. 1 FUEL TUBE PROTECTOR 
    1. Remove the 2 clips and unfasten the claw, and then remove the No. 1 fuel tube protector.
      Fig 2: Identifying No. 1 Fuel Tube Protector
      G05239101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 1 FUEL TANK PROTECTOR 
    Fig 3: Identifying No. 1 Fuel Tank Protector
    G05271590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 4 nuts, and then remove the No. 1 fuel tank protector.
  18. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    Fig 4: Identifying No. 1 Fuel Tank Protector Sub-Assembly
    G05271591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 clips (A) and 6 nuts, and then remove the No. 1 fuel tank protector.
  19. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel pump tube.
      1. Pinch the projection of the retainer to remove the lock claws and pull it down.
        2. Fig 5: Identifying Fuel Pump Tube
        G05271592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Pull out the fuel pump tube.
        NOTE:
        • Check if there is any dirt or mud around the connector before this operation and remove the dirt if necessary.
        • Be careful of mud because the quick connector can be contaminated.
        • Do not use any tool in this operation.
        • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
        • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
    2. Disconnect the fuel tank vent hose.
      1. Deeply push the connector to release the locking tab.
      2. Pinch portion A.
      3. Pull out the connector.
      Fig 6: Identifying Fuel Tank Vent Hose
      G05239105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 3 fuel tank breather tube.
      1. Pinch the tube connector and then pull out the No. 3 fuel tank breather tube.
        NOTE:
        • Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
        • Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
        • Do not use any tool in this operation.
        • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
        • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
        Fig 7: Identifying Fuel Tank Breather Tube No. 3
        G05271594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
      Fig 8: Locating Hose Clamp Bolt
      G05239107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Set up a transmission jack under the fuel tank.
    6. Remove the 4 bolts, and then remove the 2 fuel tank bands.
    7. Remove the 2 nuts.
    8. Operate the transmission jack to remove the fuel tank.
      Fig 9: Identifying Fuel Tank Bolts & Nuts
      G05239108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Unfasten the 2 claws, and then remove the fuel pump tube.
      Fig 10: Identifying Fuel Pump Tube Claws
      G05239109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the hose clamp bolt, and then remove the fuel tank to filler pipe hose.
      Fig 11: Identifying Hose Clamp Bolt
      G05239110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK VENT HOSE 
    1. Completely push the connector to release the locking tab (*1).
    2. Pinch portion A (*2).
    3. Pull out the connector.
    4. Unfasten the claw, and then remove the fuel tank vent hose.
      Fig 12: Identifying Fuel Tank Vent Hose
      G05239111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the No. 1 evaporation vent tube.
      NOTE:
      • Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
      • Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
      • Do not use any tool in this operation.
      • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
      Fig 13: Identifying No. 1 Evaporation Vent Tube
      G05239112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSEMBLY 
    1. Using SST, loosen the fuel pump gauge retainer.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      NOTE: Loosen the retainer by turning it counterclockwise while holding the SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.

      HINT:

      A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.

    2. Remove the fuel pump gauge retainer.
      Fig 14: Identifying Fuel Pump Gauge Retainer
      G05239113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel tank over fill check valve assembly.
      Fig 15: Identifying Fuel Tank & Valve Assembly
      G05239114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the tank suction tube support and gasket from the fuel tank.
      Fig 16: Identifying Retainer & Gasket
      G05239115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TANK SUCTION TUBE SUPPORT 
    1. Remove the tank suction tube support from the fuel tank.
      Fig 17: Identifying Tank Suction Tube Support
      G05239116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FUEL TANK SIDE PLATE 
    1. Remove the bolt and nut; and then remove the fuel tank side plate and the fuel tank bracket.
    Fig 18: Identifying Fuel Tank Side Plate
    G05239120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FUEL TANK CUSHION SET 
    1. Remove the fuel tank cushion sets and No. 5 fuel tank cushions.
    Fig 19: Identifying Fuel Tank Cushion Sets & No. 5 Fuel Tank Cushions
    G05239118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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