Fuel Tank: Removal: Removal

DISCHARGE FUEL SYSTEM PRESSURE
1. Discharge fuel system pressure. Refer to PRECAUTION .).
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 .
REMOVE REAR SEAT CUSHION ASSEMBLY . Refer to REMOVAL - Step 3
REMOVE NO. 3 ROOM PARTITION PAD See step 4
REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER See step 5
REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY See step 6
DRAIN FUEL
REMOVE REAR FLOOR SERVICE HOLE COVER
1. Remove the rear floor service hole cover.
  
  Fig 1: Identifying Rear Floor Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL SENDER GAUGE
1. Disconnect the fuel sender gauge connector.
  
  Fig 2: Identifying Fuel Sender Gauge Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 5 bolts and fuel sender gauge from the fuel tank.
  
  Fig 3: Identifying Fuel Sender Gauge Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Be careful not to bend the arm of the fuel sender gauge.
REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR . Refer to REMOVAL - Step 15
REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
HINT:

Use the same procedure as for the No. 2 differential support protector.
REMOVE NO. 2 FLOOR UNDER COVER . Refer to REMOVAL - Step 1
REMOVE NO. 1 FLOOR UNDER COVER . Refer to REMOVAL - Step 2
REMOVE FRONT EXHAUST PIPE ASSEMBLY
HINT:

Refer to REMOVAL .
REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
HINT:

Refer to REMOVAL .
REMOVE REAR SUSPENSION REAR LOWER MEMBER BRACE LH . Refer to REMOVAL - Step 47
REMOVE REAR SUSPENSION REAR LOWER MEMBER BRACE RH . Refer to REMOVAL - Step 48
DISCONNECT PARKING BRAKE CABLE ASSEMBLY
1. Remove the 2 parking brake cable assemblies from the 4 clamps.
  
  Fig 4: Identifying Parking Brake Cable Assemblies, Clamps, & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts and disconnect the 2 parking brake cable assemblies.
3. Remove the bolt, loosen the grommet then remove No. 3 fuel tank protector.
  
  Fig 5: Identifying Fuel Tank Protector Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the bolt, loosen the grommet then remove No. 4 fuel tank protector.
DISCONNECT FUEL TUBE SUB-ASSEMBLY
1. Disconnect the fuel tank main tube (LH side).
  
  Fig 6: Disconnecting Fuel Tank Main Tube (LH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any dirt and foreign matter on the fuel tube connector before performing this work.
  - Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
  - 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 after disconnecting the fuel pump tube.
  - If the fuel tube connector and pipe are stuck, push and pull on them to release them.
2. Disconnect the fuel tank return vent tube.
  
  Fig 7: Disconnecting Fuel Tank Return Vent Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any dirt and foreign matter on the fuel tube connector before performing this work.
  - Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
  - 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 after disconnecting the fuel pump tube.
  - If the fuel tube connector and pipe are stuck, push and pull on them to release them.
3. Disconnect the fuel tank main tube (RH side).
  
  Fig 8: Disconnecting Fuel Tank Main Tube (RH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Remove any dirt and foreign matter on the fuel tube connector before performing this work.
  - Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
  - 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 after disconnecting the fuel pump tube.
  - If the fuel tube connector and pipe are stuck, push and pull on them to release them.
DISCONNECT FUEL TANK TO FILLER PIPE HOSE
1. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
  
  Fig 9: Connecting Fuel Tank To Filler Pipe Hose With Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FUEL TANK VENT HOSE
1. Remove the clamp and disconnect the fuel tank vent hose.
REMOVE FUEL TANK ASSEMBLY
1. Place an engine lifter under the fuel tank assembly.
  
  Fig 10: Identifying Fuel Tank Bands Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 bolts and fuel tank bands.
3. Slightly lower the engine lifter.
  
  Fig 11: Disconnecting Fuel Tank Breather Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disconnect the No. 1 fuel tank breather tube sub-assembly and remove the fuel tank assembly.
  NOTE:
  - Remove any dirt and foreign matter on the fuel tube connector before performing this work.
  - Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
  - 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 after disconnecting the fuel pump tube.
  - If the fuel tube connector and pipe are stuck, push and pull on them to release them.
REMOVE NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
1. Remove the 4 bolts, No. 1 fuel tank breather tube sub-assembly and gasket.
  
  Fig 12: Identifying Fuel Tank Breather Tube Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TUBE SUB-ASSEMBLY
1. Remove the clamp and remove the fuel tank main tube and fuel tank return vent tube.
  
  Fig 13: Identifying Fuel Tank Main Tube And Fuel Tank Return Vent Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 clamps and remove the edge protector.
  
  Fig 14: Identifying Edge Protector Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 tank bracket retainer sub-assemblies.
  
  Fig 15: Removing Tank Bracket Retainer Sub-Assemblies
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK TO FILLER PIPE HOSE
1. Loosen the hose clamp bolt and remove the fuel tank to filler pipe hose from the fuel tank assembly.
  
  Fig 16: Identifying Fuel Tank To Filler Pipe Hose From Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK VENT HOSE
1. Remove the clip and fuel tank vent hose.
  
  Fig 17: Identifying Fuel Tank Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK CUSHION
1. Remove the 11 fuel tank cushions shown in the illustration.
  
  Fig 18: Identifying Fuel Tank Cushions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 FUEL TANK PROTECTOR
1. Remove the No. 1 fuel tank protector from the fuel tank assembly.
  
  Fig 19: Identifying No. 2 Fuel Tank Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002