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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 disable the SRS system.
    NOTE:
    • w/ Navigation System:

      After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  3. REMOVE REAR SEAT ASSEMBLY 
    1. Remove the rear No. 1 seat assembly and rear No. 2 seat assembly (See REMOVAL ).
  4. REMOVE FRONT FLOOR CARPET ASSEMBLY 
    1. Fold back the floor carpet.

      HINT:

      Fold back the carpet until it is possible to remove the air duct.

      Fig 1: Folding Back Floor Carpet
      G05628894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Remove the 2 screws and air duct.
      Fig 2: Locating Air Duct Screws
      G05628895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the service hole cover.
  6. REMOVE FUEL TANK CAP ASSEMBLY 
    Fig 3: Identifying Service Hole Cover
    G05759613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the 5 bolts and fuel tank protector.
      Fig 4: Locating Fuel Tank Protector Bolts
      G05628891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Detach the fuel tube clamp.
    2. Pull up the retainer and disconnect the fuel tank main tube.
      NOTE:
      • Check for foreign matter 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 foreign matter on the pipe seal surface. Clean if necessary.
      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
      • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
        Fig 5: Disconnecting Fuel Tank Main Tube
        G05759615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DRAIN FUEL 
    1. Connect the cable to the negative (-) battery terminal.
      NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
    2. Connect the Techstream to the DLC3.
    3. Turn the engine switch on (IG).
      NOTE: Do not start the engine.
    4. Turn the Techstream main switch on.
    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
      CAUTION:
      • Do not smoke or be near an open flame when working on the fuel system.
      • Secure good ventilation.
      • Keep gasoline away from rubber or leather parts.

      HINT:

      If the fuel pump does not operate, remove the fuel tube joint clip and No. 1 fuel tube joint, and drain fuel from the port shown in the illustration.

      Fig 6: Identifying Port
      G05628893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the fuel pump and fuel sender gauge connector.
    7. Disconnect the cable from the negative (-) battery terminal.
      CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
      NOTE:
      • w/ Navigation System:

        After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

      • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
    Fig 7: Locating Fuel Pump And Fuel Sender Gauge Connector
    G05628897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY 
    1. Detach the fuel tube clamp.
    2. Pull up the retainer and disconnect the fuel tank return tube.
      Fig 8: Disconnecting Fuel Tank Return Tube
      G05628898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for foreign matter 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 foreign matter on the pipe seal surface. Clean if necessary.
      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
      • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
  11. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Detach the 2 fuel tube clamps.
    2. Pull up the retainer and disconnect the fuel tank breather tube.
      NOTE:
      • Do not use any tools in this procedure.
      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
        Fig 9: Disconnecting Fuel Tank Breather Tube
        G05759619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Detach the fuel tube clamp.
    2. Disconnect the fuel tank breather tube.
      Fig 10: Disconnecting Fuel Tank Breather Tube
      G05759620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for foreign matter 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 foreign matter on the pipe seal surface. Clean if necessary.
      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
      • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
  13. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Disconnect the fuel tank to filler pipe hose from the fuel tank filler pipe.
  14. REMOVE FUEL TANK SUB-ASSEMBLY 
    1. Place a transmission jack under the fuel tank.
      Fig 11: Locating Filler Pipe Hose
      G05628901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.
    3. Slowly lower the transmission jack slightly.
      Fig 12: Locating Fuel Tank Bands Bolts
      G05628902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY 
    1. Remove the 3 fuel tube joint clips and pull out the 2 fuel tubes and No. 1 fuel tube joint.
      NOTE:
      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.
      • 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 step 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 13: Pulling Out Fuel Tubes And Fuel Tube Joint
        G05759623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel main tube and fuel return tube from the fuel tank.
  16. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See REMOVAL  )
    Fig 14: Locating Fuel Main Tube And Fuel Return Tube
    G05628904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Remove the fuel tank to filler pipe hose from the fuel tank.
      Fig 15: Locating Fuel Tank To Filler Pipe Hose
      G05628906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE NO. 1 FUEL TANK HEAT INSULATOR 
    1. Remove the fuel tube clamp from the No. 1 fuel tank heat insulator.
    2. Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the No. 1 fuel tank heat insulator.
      Fig 16: Removing Fuel Tank Heat Insulator
      G05628907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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