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Fuel Tank: Removal

  1. PRECAUTION  (See REMOVAL  )
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Remove the circuit opening relay (C/OPN) and discharge fuel system pressure (see PRECAUTION  ).
  3. REMOVE REAR NO. 1 SEAT ADJUSTER ASSEMBLY (for Power Seat) 
    1. Remove the rear No. 1 seat adjuster assembly (see REMOVAL ).
  4. REMOVE REAR NO. 1 SEAT ADJUSTER ASSEMBLY (for Ottoman) 
    1. Remove the rear No. 1 seat adjuster assembly (see REMOVAL ).
  5. REMOVE REAR NO. 2 SEAT ADJUSTER ASSEMBLY (for Power Seat) 
    1. Remove the rear No. 2 seat adjuster assembly (see REMOVAL ).
  6. REMOVE REAR NO. 2 SEAT ADJUSTER ASSEMBLY (for Ottoman) 
    1. Remove the rear No. 2 seat adjuster assembly (see REMOVAL ).
  7. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)  (See REMOVAL )
  8. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY  (See REMOVAL )
  9. REMOVE BATTERY SERVICE HOLE COVER LH  (See REMOVAL )
  10. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  11. REMOVE BATTERY SERVICE HOLE COVER  (See REMOVAL )
  12. REMOVE SERVICE PLUG GRIP  (See REMOVAL )
  13. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the 2 connectors.
      Fig 1: Locating Connectors Service Hole Cover
      G05773040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Disconnect the fuel tank main tube and fuel tank return vent tube
      1. Remove the 2 tube joint clips and disconnect the 2 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 2: Locating Fuel Tank Vent Tube Set Plate
          G05387666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, No. 2 fuel tank protector and fuel tank vent tube set plate.
      3. Fig 3: Locating No. 2 Fuel Tank Protector Bolts
      G05773042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Remove the fuel suction with pump and gauge tube from the fuel tank
      NOTE:
      • Make sure that the sender gauge arm does not bend.
      • Do not damage the fuel suction with pump and gauge tube.
    2. Disconnect the fuel hose.
      3. Fig 4: Locating Fuel Hose Clip
      G05773043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the gasket
  16. DRAIN FUEL 
  17. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the fuel sender gauge connector.
      Fig 5: Locating Rear Floor Service Hole Cover
      G05773044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Remove the 5 screws and fuel sender gauge assembly.
      2. Fig 6: Locating Fuel Sender Gauge Assembly Bolts
      G05773045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 
    1. Remove the propeller with center bearing shaft (see REMOVAL )
  20. REMOVE FUEL TANK FILLER PIPE PROTECTOR 
    1. Remove the 2 clips, 2 nuts and tank protector.
      Fig 7: Locating Tank Protector And Clip
      G05773046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL TANK PROTECTOR BRACKET SIDE 
    1. Remove the 2 bolts and protector bracket.
      Fig 8: Locating Tank Protector And Clip
      G05773047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 main tube.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
        Fig 9: Locating Fuel Tank Main Tube RH
        G05773048Courtesy 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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 main tube.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
        Fig 10: Locating Fuel Tank Main Tube LH
        G05773049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT FUEL TANK RETURN VENT TUBE 
    1. Disconnect the fuel tank return vent tube
      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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 return vent tube.
      • If the pipe and connector are stuck together, pinch the vent tube between your fingers and turn it carefully to free it. Then disconnect the fuel return vent tube.
        Fig 11: Locating Fuel Tank Return Vent Tube
        G05773050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose.
      1. Pinch the retainer and lower it to disconnect the fuel tank vent hose
        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 allow any scratches or foreign matter on the parts when disconnecting them, as the vent hose contains the O-rings that seal the plug.
        • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
        • 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 vent hose.
        • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.
          Fig 12: Locating Retainer Location
          G05773051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel suction tube
      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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 suction tube.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the suction tube.
        Fig 13: Locating Fuel Suction Tube
        G05773052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT FUEL TANK WIRE 
    1. Disconnect the fuel vapor containment valve connector and detach the 2 clamps.
      Fig 14: Locating Fuel Vapor Containment Valve Connector And Clamps
      G05773053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FUEL TANK ASSEMBLY 
    1. Place a mission jack under the fuel tank
    2. Remove the 4 bolts and 2 fuel tank bands.
      Fig 15: Locating Fuel Tank Assembly Bolts
      G05773054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Slide the filler pipe clamp and disconnect the fuel tank from the fuel filler pipe, and lower the mission jack.
      4. Fig 16: Sliding Filler Pipe Clamp
      G05773055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Slowly lower the mission jack slightly
      NOTE: Make sure that no load is applied to the fuel filler pipe.
    5. Lower the mission jack to remove the fuel tank from the vehicle
      NOTE: Do not allow the fuel tank to contact the vehicle, especially the differential.

      HINT

      Lower the mission jack slowly.

  28. REMOVE FUEL TANK PRESSURE SENSOR 
    1. Remove the fuel tank pressure sensor (see REMOVAL ).
  29. REMOVE FUEL TANK WIRE 
    1. Detach the 6 clamps of the fuel tank wire to remove the wire from the fuel tank.
      Fig 17: Locating Fuel Tank Clamps
      G05773056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Remove the fuel suction tube
      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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 suction tube.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the suction tube.
        Fig 18: Removing Fuel Suction Tube Sub-Assembly
        G05773057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose sub-assembly.
      1. Push the hose firmly toward the fuel tank.
        2. Fig 19: Pushing Hose To Fuel Tank
        G05773058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Pinch the hose (portion A) as shown in the illustration.
      3. Pull out the hose.
        NOTE:
        • Do not use any tools in this procedure.
        • Check for any dirt and foreign matter contamination in the fuel tank and around the hose. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the canister and hose.
  32. REMOVE FUEL TANK RETURN VENT TUBE 
    1. Remove the return vent tube from the fuel tank
      Fig 20: Locating Fuel Tank Return Vent Tube
      G05773059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Detach the 6 clamps and fuel tank main tube from the fuel tank.
      2. Fig 21: Locating Fuel Tank Protector And Clamps
      G05773060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel tube 6 clamps
  34. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the fuel tank protector from the fuel tank
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