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Fuel Tank: Removal

  1. PRECAUTION (See  REMOVAL   ) 
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (see PRECAUTION  ).
  3. REMOVE COWL TOP VENTILATOR LOUVER RH  (See REMOVAL )
  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE: 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.
  5. REMOVE REAR SEAT ASSEMBLY (for Power Seat) 
    1. Remove the rear seat assembly (see REMOVAL ).
  6. REMOVE REAR SEAT ASSEMBLY (for Ottoman) 
    1. Remove the rear seat assembly (see REMOVAL ).
  7. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type) 
    1. Remove the rear seat cushion assembly (see REMOVAL ).
  8. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER (See  REMOVAL   ) 
  9. REMOVE FUEL TANK MAIN AND RETURN TUBE 
    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 1: Locating Tube Joint Clips
          G06186699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the fuel sender gauge connector.
      2. Fig 2: Locating Fuel Sender Gauge Connector
      G04948090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    1. Remove the front exhaust pipe (see REMOVAL ).
  12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 
    1. Remove the propeller with center bearing shaft (see REMOVAL ).
  13. REMOVE FUEL TANK FILLER PIPE PROTECTOR 
    1. Remove the 2 nuts.
    2. Detach the 2 clips and protector.
      Fig 3: Locating Clips And Protector
      G06186759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL TANK PROTECTOR BRACKET SIDE 
    1. Remove the 2 bolts and protector bracket.
      Fig 4: Locating Protector Bracket Bolts
      G06186760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel tank main 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 main tube.
        Fig 5: Locating Fuel Tank Main Tube
        G04948091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • 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.
    2. 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 fuel return 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 tube.
        Fig 6: Locating Fuel Tank Return Vent Tube
        G06186762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Loosen the clamp and disconnect the filler pipe hose.
      Fig 7: Locating Filler Pipe Hose Clamp
      G04948093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place a transmission jack under the fuel tank.
    5. Remove the 4 bolts and 2 fuel tank bands.
    6. Lower the transmission jack so that the fuel tank breather tube can be disconnected.
      NOTE: Make sure that no load is applied to the fuel filler pipe.

      HINT:

      Lower the transmission jack slowly.

      Fig 8: Locating Fuel Tank Bolts
      G04948094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the fuel tank breather 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 breather 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 breather tube.
        Fig 9: Locating Fuel Tank Breather Tube
        G04948095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the fuel tank vent hose.
      1. Pinch the retainer and then raise it.
        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 10: Pinching Retainer
          G06186766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Lower the transmission jack to remove the fuel tank from the vehicle.
      NOTE:
      • Do not allow the fuel tank to contact the vehicle, especially the differential.
      • Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.

      HINT:

      Lower the transmission jack slowly.

  16. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Remove the 8 bolts and, lower fuel tank protector and fuel vent tube set plate.
      Fig 11: Locating Lower Fuel Tank Protector And Fuel Vent Tube Set Plate Bolts
      G04947944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel hose.
    3. 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 tube with pump and gauge tube.
    4. Remove the gasket.
      Fig 12: Locating Fuel Hose
      G04947945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Remove the 5 screws and fuel sender gauge.
    2. Remove the gasket.
      Fig 13: Locating Fuel Sender Gauge Screws
      G04948099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the 6 clamps and fuel tank main tube from the fuel tank.
      Fig 14: Locating Fuel Tank Main Tube Clamps
      G04948100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel hose clamp.
      Fig 15: Locating Fuel Hose Clamp
      G04948101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 FUEL TANK PROTECTOR 
    1. Remove the bolt and clip and No. 2 fuel tank protector from the fuel tank.
    2. Remove the clamp from the fuel tank.
      Fig 16: Locating No. 2 Fuel Tank Protector Bolt And Clip
      G04948102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. 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 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 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 17: Disconnecting Fuel Tank Vent Hose
        G04948103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL TANK CUSHION 
    1. Remove the 3 tank cushions.
      Fig 18: Identifying Tank Cushions
      G04948104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the tank protector and 5 tank cushions.
      Fig 19: Identifying Tank Cushions
      G04948105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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