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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (See FUEL SYSTEM )

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE EXHAUST PIPE ASSEMBLY CENTER 

    (See REMOVAL )

  4. REMOVE FRONT FLOOR HEAT INSULATOR NO.3 
    1. Remove the 5 nuts and front floor heat insulator No.3
    Fig 1: Locating Front Floor Heat Insulator With Nuts
    G05200892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY NO.1 
    1. Disengage the 4 grommets.
    2. Remove the screw and fuel tank protector sub-assembly No.1
    Fig 2: Locating Fuel Tank Protector Sub-Assembly No.1 With Grommets
    G05200893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. SEPARATE PARKING BRAKE CABLE ASSEMBLY NO.3 
    1. Remove the nut and disconnect the parking brake cable assembly No.3
    Fig 3: Locating Parking Brake Cable Assembly Nut
    G05200894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT FUEL TANK WIRE 
    1. Separate the fuel tank wire connector from the bracket.
    2. Disconnect the 2 connectors.
    Fig 4: Locating Fuel Tank Wire Connectors
    G05200895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CHARCOAL CANISTER PROTECTOR 
    1. Disconnect the clamp from the charcoal canister protector.
    2. Remove the 3 bolts and charcoal canister protector.
    Fig 5: Locating Charcoal Canister Protector With Clamp
    G05200896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT CHARCOAL CANISTER FUEL HOSE 
    1. Disconnect the charcoal canister fuel hose from the charcoal canister assembly.
    1. Pinch the retainer and pull out the quick connector with the quick connector pushed to the pipe side to disconnect the charcoal canister fuel hose from the charcoal canister assembly.
    NOTE:
    • Remove dirt or foreign objects on the quick connector before this work.
    • Be careful not to allow foreign matter to scratch or come into contact with the pipe that is sealed by O-rings.
    • Perform this work by hand. Do not use any tools.
    • Do not forcibly bend, kink, twist or turn the nylon tube.
    • Protect the connected part by covering it with a plastic bag after disconnecting the charcoal canister fuel hose.
    • If the quick connector and pipe are stuck, push and pull them to release.
    Fig 6: Disconnecting Charcoal Canister Fuel Hose
    G05200897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Pinch the tabs of the retainer to disengage the lock claws and pull the retainer down as shown in the illustration.
    2. Pull out the fuel tank main tube.
    NOTE:
    • Check for dirt or other foreign objects around the connector before this operation. Clean the connector as necessary.
    • Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by O-rings.
    • Do not use any tools for this operation.
    • Do not damage the disconnected pipe or connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
    • When the pipe and connector are stuck, push and pull the connector to release. Pull out the connector carefully.
    Fig 7: Pinching Tabs Of Retainer
    G05200898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT BREATHER LOWER TUBE 
    1. Remove the checker of the breather lower tube connector.
    2. Pinch the retainer of the breather lower tube connector, and pull out the breather lower tube connector to disconnect the breather lower tube from the fuel tank.
    NOTE:
    • Check for dirt around the connector before this operation. Remove the dirt as necessary.
    • Be careful not to allow mud or foreign matter to scratch or come into contact with the pipe and connector that are sealed by O-rings.
    • Do not use any tool in this operation.
    • Do not damage the disconnected pipe or connector. Prevent intrusion of foreign objects by covering the pipe and connector with a plastic bag.
    • When the pipe and the connector are stuck, push and pull the connector to release. Pull out the connector carefully.
    Fig 8: Pinching Retainer Of Breather Lower Tube Connector
    G05200899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK ASSEMBLY 
    1. Set a transmission jack to the fuel tank.
    2. Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
      Fig 9: Locating Fuel Tank Inlet Pipe With Tube Connector And Clamp
      G05200900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts and the fuel tank bands.
      4. Fig 10: Locating Fuel Tank Bands With Bolts
      G05200901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Operate the transmission jack, and disconnect the fuel inlet pipe.
    5. Operate the transmission jack, and remove the fuel tank.
  13. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Disconnect the fuel pump connector.
    2. Disconnect the clamp and vapor pressure sensor connector.
      Fig 11: Locating Vapor Pressure Sensor Connector
      G05200862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the tube joint clip and clamp, and pull out the fuel pump tube.
      NOTE:
      • Check for dirt around the fuel tube joint before this work. Clean the dirt away as necessary.
      • Be careful not to allow dirt or foreign matter to scratch or come into contact with the fuel tube connector and fuel suction plate that are sealed by O-rings.
      • Do not use any tools in this work.
      • Do not bend, kink or twist the nylon tube by force.
      • Cover the disconnected fuel tube joint with a plastic bag.
      • When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube with the fingers, and turn it carefully to release. Disconnect the fuel tank tube.
      Fig 12: Locating Tube Joint Clip And Clamp
      G05200903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 8 bolts, fuel tank vent tube set plate and fuel pump connector plate.
      Fig 13: Locating Fuel Tank Vent Tube Set Plate And Fuel Pump Connector Plate
      G05200864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Pull out the fuel pump assembly from the fuel tank.
      NOTE:
      • Do not damage the fuel pump filter.
      • Be careful not to bend the arm of the sender gauge.
        • Fig 14: Identifying Out Fuel Pump Assembly
        G05200865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the gasket from the fuel suction tube.
  14. DRAIN FUEL 
  15. REMOVE FUEL VAPOR CONTAINMENT VALVE 
    1. Disconnect the connector and clamp.
      Fig 15: Locating Fuel Vapor Containment Valve Connector And Clamp
      G05200906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts from the fuel vapor containment valve.
      Fig 16: Locating Fuel Vapor Containment Valve With Nuts
      G05200907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
      4. Fig 17: Pulling Out Fuel Tank Vent Hose
      G05200908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Pinch portion A.
    5. Pull out the fuel tank vent hose.
    6. Remove the fuel vapor containment valve from the fuel tank.
  16. REMOVE FUEL TANK WIRE 
    1. Disconnect the 4 clamps and remove the fuel tank wire.
    Fig 18: Locating Fuel Tank Wire Clamp
    G05200909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the fuel tank main tube from the clamp.
    Fig 19: Locating Fuel Tank Main Tube
    G05200910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE CLAMP 
    1. Remove the 2 clamps of the fuel tank main tube from the fuel tank.
      Fig 20: Locating Clamps On Fuel Tank
      G05200911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamp from the fuel tank.
      Fig 21: Locating Fuel Tank Clamp
      G05200912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL TANK CUSHION 
    1. Remove the 8 fuel tank cushions from the fuel tank.
    Fig 22: Identifying Fuel Tank Cushions
    G05200913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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