Fuel Tank: Removal

REMOVE REAR SEAT CUSHION ASSEMBLY (See REMOVAL )
DISCHARGE FUEL SYSTEM PRESSURE (See REMOVAL )
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.
REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER
REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

Fig 1: Identifying Fuel Tank Vent Tube Set Plate
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- These procedures should be performed with the fuel tank less than 1/4 full.
- Check for dirt 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 in these procedures.
- Do not forcefully bend or twist the nylon tube.
- Check for dirt contamination on the pipe seal's 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.
1. Disconnect the connector in the fuel tank side.
  1. Remove the tube joint clip.
  2. Pull out the fuel main tube.
  3. Plug the port of the fuel suction plate with a clean rubber cap.
2. Disconnect the connector on the fuel pipe side.
  1. Clean the pipe before the operation.
  2. Pull out the connector, holding the claw of the retainer as shown in the illustration.
    NOTE: If the connector and the pipe are stuck together, release them by pushing and pulling them by hand.
    
    HINT:
    
    Do not remove the retainer when it is reinstalled.
    
    Fig 2: Identifying Connector On Fuel Pipe Side
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Protect each connecting part from damage and contamination by covering it with a plastic bag.
REMOVE REAR FLOOR SERVICE HOLE COVER
1. Remove the service hole cover and disconnect the fuel sender gauge connector.
REMOVE FRONT FLOOR BRACE CENTER (See REMOVAL )
REMOVE NO. 2 ENGINE UNDER COVER (See REMOVAL )
REMOVE EXHAUST PIPE ASSEMBLY
1. Remove the exhaust pipe assembly (see REMOVAL ).
REMOVE PROPELLER SHAFT HEAT INSULATOR
REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR
1. Remove the 2 bolts and propeller shaft heat insulator.
REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
REMOVE PROPELLER SHAFT ASSEMBLY (See REMOVAL )
REMOVE NO. 2 PARKING BRAKE CABLE ASSEMBLY
REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY
REMOVE FUEL TANK TO FILLER PIPE HOSE
1. Disconnect the air inlet hose from the filler pipe.
2. Disconnect the breather hose from the filler pipe.
3. Disconnect the fuel inlet tube from the filler pipe.
4. Remove the 2 bolts and filler pipe.
DISCONNECT VENT LINE HOSE
1. Disconnect the hose from the canister.
REMOVE FUEL TANK ASSEMBLY
1. Using a mission jack, support the fuel tank.
2. Remove the 4 bolts.
3. Disconnect the No. 1 fuel tank band and remove the fuel tank.
REMOVE FUEL TANK VENT TUBE SET PLATE
1. Remove the 8 bolts and set plate.
REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY
1. Lift up the fuel pump and sender gauge. Disconnect the fuel sub-suction hose from the fuel return jet tube, and remove the fuel pump, sender gauge and gasket.
  NOTE:
  - Do not damage the fuel pump filter.
  - Be careful not to bend the arm of the sender gauge.
    
    Fig 3: Identifying Fuel Sub-Suction Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SENDER GAUGE
1. Remove the 5 screws, sender gauge and gasket.
REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY
REMOVE VENT LINE HOSE