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Fuel Tank: Removal: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT: 

    Refer to PRECAUTION .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
  3. REMOVE REAR SEAT CUSHION ASSEMBLY  . Refer to REMOVAL - Step 1
  4. REMOVE REAR FLOOR SERVICE HOLE COVER  See step  4
  5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY  See step  5
  6. REMOVE FUEL TANK VENT TUBE SET PLATE  See step  6
  7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE  See step  7
  8. DRAIN FUEL 
  9. REMOVE CENTER EXHAUST PIPE ASSEMBLY 

    HINT: 

    Refer to REMOVAL .

  10. REMOVE FRONT FLOOR BRACE RH 
    1. Remove the bolt and 2 nuts, and remove the front floor brace RH.
      Fig 1: Identifying Front Floor Brace Bolts And Nuts RH Location
      GTY147369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT FLOOR BRACE LH 
    1. Remove the bolt and 2 nuts, and remove the front floor brace LH.
      Fig 2: Identifying Front Floor Brace LH Bolts And Nuts Location
      GTY132350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the set bolt and set nut of the No. 2 parking brake cable assembly.
      Fig 3: Identifying No. 2 Parking Brake Cable Assembly With Bolt And Nut Location
      GTY140409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the set bolt and set nut of the No. 3 parking brake cable assembly.
      Fig 4: Identifying Set Bolt And Set Nut Of No. 3 Parking Brake Cable Assembly
      GTY146865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE REAR STABILIZER BAR NO. 1 BRACKET 
    1. Remove the 4 bolts and 2 rear stabilizer bar No. 1 brackets.
      Fig 5: Identifying Rear Stabilizer Bar No. 1 Brackets With Bolts Location
      GTY147368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK PROTECTOR LOWER CENTER 
    1. Remove the 4 bolts and 2 clips.
      Fig 6: Identifying Bolts And Clips (For Se Grade)
      GTY142926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel tank protector.
  16. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel pump tube.
      Fig 7: Pinching Tab Of Retainer To Disengage Lock Claws
      GTY130419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Pinch the tab of the retainer to disengage the lock claws and pull it down as shown.
      2. Pull out the fuel tank main tube.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
        • It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.
    2. Disconnect the No. 1 fuel tube.
      Fig 8: Pulling Out Fuel Tube No. 1
      GTY143039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Pinch the tube connector and then pull out the No. 1 fuel tube.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
        • It is necessary to prevent mud or dirt from entering the quick connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes. Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling the connector to release it. Pull the connector off the pipe carefully.
    3. Place a transmission jack under the fuel tank assembly.
      Fig 9: Placing Transmission Jack Under Fuel Tank Assembly
      GTY124624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 set bolts of the fuel tank bands. (* 1)
      Fig 10: Identifying Fuel Tank Bands Bolts
      GTY129516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the hose clamp and disconnect the fuel tank to filter pipe hose. (* 2)
    6. Slightly lower the transmission jack.
    7. Disconnect the fuel tank vent hose from the charcoal canister. (* 3)
      1. Push the connector deep into the charcoal canister to release the locking pin.
      2. Pinch portion A.
      3. Pull out the connector.
    8. Remove the fuel tank.
    9. Remove the 2 pins and 2 fuel tank bands as shown.
      Fig 11: Identifying Pins And Fuel Tank Bands
      GTY144982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 4 clip nuts.
      Fig 12: Identifying Clip Nuts (For Se Grade)
      GTY146928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK VENT HOSE 
    1. Push the connector deep into the charcoal canister to release the locking pin.
      Fig 13: Identifying Fuel Tank Vent Hose
      GTY144983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch portion A.
    3. Pull out the connector.
  18. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Remove the fuel pump tube from the fuel main tube support.
      Fig 14: Identifying Fuel Pump Tube
      GTY124805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL MAIN TUBE SUPPORT 
    1. Remove the bolt and tube support.
      Fig 15: Identifying Fuel Main Tube Support Bolt Location
      GTY144984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 2 FUEL TANK CUSHION 
    1. Remove the 7 No. 2 fuel tank cushions.
      Fig 16: Identifying No. 2 Fuel Tank Cushions
      GTY144985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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