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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See FUEL SYSTEM .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE REAR SEAT CUSHION ASSEMBLY  (See REMOVAL )
  4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER  (See REMOVAL )
  5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See REMOVAL )
  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
    G05750128Courtesy 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
      G05750129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and fuel sender gauge.
    3. Remove the fuel sender gauge from the fuel tank.
    NOTE: Be careful not to bend the arm of the fuel sender gauge.
    Fig 3: Locating Fuel Sender Gauge Bolts
    G05303285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    HINT:

    See REMOVAL .

  10. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY 

    HINT:

    See REMOVAL .

  11. REMOVE NO. 2 DIFFERENTIAL SUPPORT PROTECTOR  (See REMOVAL )
  12. REMOVE NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 

    HINT:

    Removal procedure of the No. 1 differential support protector is the same as that of the No. 2 differential support protector.

  13. REMOVE REAR FLOOR SIDE MEMBER COVER LH 
  14. REMOVE REAR FLOOR SIDE MEMBER COVER RH 
  15. REMOVE REAR SUSPENSION MEMBER BRACE LH 
    1. Remove the 4 bolts and suspension member brace lower LH.
    Fig 4: Locating Suspension Member Brace Lower LH Bolts
    G05752439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE REAR SUSPENSION MEMBER BRACE RH 
    1. Remove the 4 bolts and suspension member brace lower RH.
    Fig 5: Locating Suspension Member Brace Lower RH Bolts
    G05826442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 parking brake cables from the 4 clamps.
    2. Remove the 4 bolts and disconnect the 2 parking brake cables.
    Fig 6: Locating Bolts And Parking Brake Cables
    G05303295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube (LH side).
      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.
      Fig 7: Identifying Fuel Tank Main Tube (LH Side)
      G05826444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank return vent tube.
      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.
      Fig 8: Identifying Fuel Tank Return Vent Tube
      G05826445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel tank main tube (RH side).
      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.
      Fig 9: Identifying Fuel Tank Main Tube (RH Side)
      G05826446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
    Fig 10: Locating Hose Clamp Bolt
    G05750136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel hose clamp.
    2. Remove the clip and disconnect the No. 3 fuel hose sub-assembly.
    Fig 11: Locating Clip And No. 3 Fuel Hose Sub-Assembly
    G05826448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tube clamp.
    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.
    Fig 12: Identifying Fuel Tank To Canister Tube Sub-Assembly
    G05826449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK ASSEMBLY 
    1. Place a engine lifter under the fuel tank assembly.
    2. Remove the 4 bolts, fuel tank bands and fuel tank assembly.
    Fig 13: Locating Bolts, Fuel Tank Bands And Fuel Tank Assembly
    G05303303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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: Locating Bolts, No. 1 Fuel Tank Breather Tube Sub-Assembly And Gasket
    G05826451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the clamp and remove the fuel tank main tube and fuel tank return vent tube.
      Fig 15: Locating Clamp Of Fuel Tank Main Tube And Fuel Tank Return Vent Tube
      G05826452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 clamps and remove the edge protector.
    Fig 16: Identifying Clamps And Edge Protector
    G05826453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. 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: Locating Hose Clamp Bolt
    G05750143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FUEL TANK VENT HOSE 
    1. Push the fuel tank vent hose deep into the fuel tank to release the lock pin.
    2. Pinch portion A.
    3. Pull out the fuel tank vent hose.
    4. Remove the fuel vapor containment valve from the fuel tank.
    Fig 18: Pinching Portion A
    G05826455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FUEL TANK CUSHION
    1. Remove the 11 fuel tank cushions shown in the illustration.
    Fig 19: Identifying Fuel Tank Cushions
    G05750145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 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
    G05750146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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