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Removal [09/2020 - ]: Procedure

  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    Refer to REMOVAL [09/2014 - ] 

  2. REMOVE FUEL TANK VENT TUBE ASSEMBLY 

    Refer to REMOVAL [09/2014 - ] 

  3. DRAIN FUEL 
  4. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY 

    Refer to REMOVAL [09/2014 - ]

  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube sub-assembly on the LH side.
      GTY508414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      Push
      Pull out
      Pull off
      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
        • Do not bend, twist, pinch or kink the nylon tube.
      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
    2. Disconnect the fuel tank main tube sub-assembly on the RH side.
      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      GTY521402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Pipe
      *b Retainer
      *c Nylon Tube
      *d Fuel Tube Connector
      *e O-ring
      *f Claw
      Push
      Pull out
      Pull off
      1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
        • Do not bend, twist, pinch or kink the nylon tube.
      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
  6. REMOVE NO. 2 FUEL TANK FILLER PIPE SUPPORT 
    1. Remove the bolt and No. 2 fuel tank filler pipe support from the No. 3 center floor cross member sub-assembly.
      GTY947950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Disconnect the fuel tank to filler pipe hose.
      NOTE:

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        GTY948253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer *b O-ring
        *c Fuel Tube Connector *d Fuel Pipe (Fuel Tank Assembly)
        Pull out Pull off
      2. If the fuel tube connector and fuel pipe (fuel tank assembly) are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe (fuel tank assembly) carefully.
        NOTE:

        Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe (fuel tank assembly).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe (fuel tank assembly) and fuel tube connector with plastic bags to prevent damage and contamination.
  8. DISCONNECT FUEL CUT OFF VALVE TUBE 
    NOTE:

    Remove any foreign matter on the fuel cut off valve tube before performing this work.

    1. Pull out the retainer to disengage the lock claws and pull off the fuel cut off valve tube.
      GTY501934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Evaporation Vent Tube Clamp
      *a Retainer
      Pull
      Pull off
      NOTE:
      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel cut off valve tube has an O-ring that seals the pipe.
      • Be sure to disconnect the fuel cut off valve tube by hand.
      • Do not bend, twist, pinch or kink the nylon tube.
    2. Disengage the clamp to disconnect the fuel cut off valve tube from the No. 1 evaporation vent tube clamp.
  9. DISCONNECT FUEL TANK BREATHER TUBE 
    NOTE:

    Remove any foreign matter on the fuel tank breather tube before performing this work.

    1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tank breather tube.
      GTY519411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Breather Tube Clamp
      *a Retainer
      *b Claw
      Pull
      Pull out
      Pull off
      NOTE:
      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank breather tube has an O-ring that seals the pipe.
      • Be sure to disconnect the fuel tank breather tube by hand.
      • Do not bend, twist, pinch or kink the nylon tube.
    2. Disengage the clamp to disconnect the fuel tank breather tube from the breather tube clamp.
  10. SEPARATE PARKING BRAKE CABLE ASSEMBLY (w/o Electric Parking Brake System) 
    1. Disengage the 4 clamps.
      GTY513902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Remove the 2 bolts and 2 nuts, and separate the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly.
  11. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 51 [03/2019 - 01/2023] , or refer to PROCEDURE - Step 57 [01/2023 - ]

  12. REMOVE REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 52 [03/2019 - 01/2023] , or refer to PROCEDURE - Step 58 [01/2023 - ]

  13. REMOVE FUEL TANK ASSEMBLY 
    1. Support the fuel tank assembly using an engine lifter.
      GTY504781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      HINT: 

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.
    3. Lower the engine lifter to remove the fuel tank assembly.
      NOTE:
      • Slowly operate the engine lifter to lower the fuel tank assembly.
      • Do not drop the fuel tank assembly.
      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.
  14. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disengage the 2 clamps to remove the fuel tank main tube sub-assembly from the fuel tank assembly.
      GTY498918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps to remove the No. 3 fuel tube clamp and No. 5 fuel tube clamp from the fuel tank assembly.
      GTY506221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 3 Fuel Tube Clamp
      *2 No. 5 Fuel Tube Clamp
  15. REMOVE FUEL TANK CUSHION 
    1. Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.
      GTY410406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set from the fuel tank assembly.
      GTY516361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank Bracket
      *2 Fuel Tank Cushion
      *3 Fuel Tank Cushion Set
      *a RH Side
      *b LH Side
  16. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.
      GTY466364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Tank Protector Sub-assembly
      *2 No. 2 Fuel Tank Protector
      *3 No. 3 Fuel Tank Protector
    2. Remove the No. 2 fuel tank protector and No. 3 fuel tank protector from the fuel tank assembly.
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