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Fuel Tank: Removal: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT: 

    Refer to PRECAUTION .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE REAR SEAT CUSHION ASSEMBLY  . Refer to REMOVAL - Step 1
  4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER  See step  4
  5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  See step  5
  6. DRAIN FUEL 
  7. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the rear floor service hole cover.
      Fig 1: Identifying Rear Floor Service Hole Cover
      GTY145265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Disconnect the fuel sender gauge connector.
      Fig 2: Locating Fuel Sender Gauge Connector
      GTY131656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and fuel sender gauge.
      Fig 3: Locating Fuel Sender Gauge Bolts
      GTY145266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel sender gauge from the fuel tank.
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge.

  9. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    HINT: 

    Refer to REMOVAL .

  10. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY 

    HINT: 

    Refer to REMOVAL .

  11. REMOVE REAR FLOOR SIDE MEMBER COVER LH 
  12. REMOVE REAR FLOOR SIDE MEMBER COVER RH 
  13. REMOVE REAR SUSPENSION MEMBER BRACE LH 
    1. Remove the 4 bolts and suspension member brace lower LH.
      Fig 4: Identifying Bolts And Suspension Member Brace Lower LH
      GTY113192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE REAR SUSPENSION MEMBER BRACE RH 
    1. Remove the 4 bolts and suspension member brace lower RH.
      Fig 5: Identifying Bolts And Suspension Member Brace Lower RH
      GTY126828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 parking brake cables from the 4 clamps.
      Fig 6: View Of Disconnecting Parking Brake Cables
      GTY128137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and disconnect the 2 parking brake cables.
  16. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube (LH side).
      Fig 7: Identifying Fuel Tank Main Tube (LH Side)
      GTY146274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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 8: View Of Disconnecting Fuel Tank Return Vent Tube
      GTY146214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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 9: View Of Disconnecting Fuel Tank Main Tube
      GTY142449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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.
  17. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
      Fig 10: View Of Connecting Fuel Tank To Filler Pipe Hose With Clamp
      GTY145269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel hose clamp.
      Fig 11: View Of Disconnecting No 3 Fuel Hose Sub-Assembly
      GTY135935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clip and disconnect the No. 3 fuel hose sub-assembly.
  19. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tube clamp.
      Fig 12: View Of Disconnecting Fuel Tank To Canister Tube Sub-Assembly
      GTY125432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank to canister tube sub-assembly.
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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.
  20. REMOVE FUEL TANK ASSEMBLY 
    1. Place a engine lifter under the fuel tank assembly.
      Fig 13: Identifying Bolts, Fuel Tank Bands And Fuel Tank Assembly
      GTY122104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts, fuel tank bands and fuel tank assembly.
  21. 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 14: Identifying Bolts, No. 1 Fuel Tank Breather Tube Sub-Assembly And Gasket
      GTY146120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the clamp and remove the fuel tank main tube and fuel tank return vent tube.
      Fig 15: View Of Disconnecting Clamp And Remove Fuel Tank Main Tube And Fuel Tank Return Vent Tube
      GTY146213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 clamps and remove the edge protector.
      Fig 16: Identifying Clamps And Edge Protector
      GTY146445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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.
      Fig 17: View Of Remove/Install Fuel Tank To Filler Pipe Hose From Fuel Tank
      GTY145270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL TANK VENT HOSE 
    1. Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
      Fig 18: View Of Pinching Portion A
      GTY125824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch portion A.
    3. Pull out the fuel tank vent hose.
    4. Remove the fuel vapor containment valve from the fuel tank.
  25. REMOVE FUEL TANK CUSHION 
    1. Remove the 11 fuel tank cushions shown in the illustration.
      Fig 19: Identifying Fuel Tank Cushions
      GTY125171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 FUEL TANK PROTECTOR 
    1. Remove the No. 2 fuel tank protector from the fuel tank assembly.
      Fig 20: Identifying No. 2 Fuel Tank Protector
      GTY146001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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