Fuel Tank: Removal: Removal

REMOVE NO. 1 REAR SEAT LEG COVER . Refer to REMOVAL - Step 1
REMOVE NO. 2 REAR SEAT LEG COVER . Refer to REMOVAL - Step 2
REMOVE REAR SEAT ASSEMBLY . Refer to REMOVAL - Step 3
REMOVE REAR FLOOR SERVICE HOLE COVER See step 4
DISCHARGE FUEL SYSTEM PRESSURE
Refer to PRECAUTION
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY See step 6
DISCONNECT FUEL TANK VENT HOSE See step 7
REMOVE FUEL PUMP GAUGE RETAINER See step 8
REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE See step 9
DRAIN FUEL
REMOVE NO. 4 FRONT FLOOR HEAT INSULATOR

Fig 1: Identifying No. 4 Front Floor Heat Insulator Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 nuts and the No. 4 front floor heat insulator from the vehicle.
REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY

Fig 2: Identifying Fuel Tank Cover Vent Case Sub-Assembly Bolt & Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the bolt and clip, and the fuel tank cover vent case sub-assembly from the vehicle.

DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Disengage the fuel tank main tube sub-assembly connector cover.

Fig 3: Identifying Fuel Tank Main Tube Sub-Assembly Connector Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Fuel Tank Main Tube Sub-assembly Connector Cover
*2	Fuel Tank Main Tube Sub-assembly Connector
*3	O-ring
*4	Fuel Tank Main Tube Sub-assembly Connector Retainer
*5	Nylon Tube
	Pinch
	Pull

Pinch the fuel tank main tube sub-assembly retainer and pull out the fuel tank main tube sub-assembly from the fuel main tube.
NOTE:
- Remove any dirt and foreign matter from the clip before performing this work.
- Avoid any scratches or foreign matter on the parts when disconnecting them, as the fuel tube connector has an O-ring that seals the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected parts by covering them with a plastic bag.
- If the fuel tube connector and pipe are stuck together, push in and pull out the fuel tube connector while squeezing the pipe to release the connection, and then disconnect the fuel tube connector.

DISCONNECT FUEL TANK VENT HOSE

Fig 4: Disconnecting Fuel Tank Vent Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Release the fuel tank vent hose connector retainer as shown in the illustration and disconnect the fuel tank vent hose from the charcoal canister assembly.

TEXT IN ILLUSTRATION

*1	Fuel Tank Vent Hose Connector Retainer
*2	Fuel Tank Vent Hose Connector
*3	O-ring
*4	Nylon Tube
	Push
	Pull

NOTE:

Remove any dirt and foreign objects from the fuel tank vent hose connector before performing the work.
Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tank vent hose connector has the O-ring that seals the pipe.
Perform the 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 vinyl bag after disconnecting the fuel tank vent hose.
If the fuel tank vent hose connector and pipe are stuck, push and pull them to release.

DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY

Disengage the fuel tank breather tube sub-assembly connector cover.

Fig 5: Disconnecting Fuel Tank Breather Tube Sub-Assembly

TEXT IN ILLUSTRATION

*1	Fuel Tank Breather Tube Sub-assembly Connector Cover
*2	Fuel Tank Breather Tube Sub-assembly Connector
*3	O-ring
*4	Fuel Tank Breather Tube Sub-assembly Connector Retainer
*5	Nylon Tube
	Pinch
	Pull

Pinch the fuel tank breather tube sub-assembly connector retainer and pull out the fuel tank breather tube sub-assembly from the fuel tank filler pipe sub-assembly.
NOTE:
- Remove any dirt and foreign matter from the clip before performing this work.
- Avoid any scratches or foreign matter on the parts when disconnecting, as the fuel tank breather tube sub-assembly connector has an O-ring that seals the plug.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected parts by covering them with a plastic bag.
- If the fuel tank breather tube sub-assembly connector and pipe are stuck together, push in and pull out the fuel tank breather tube sub-assembly connector while squeezing the pipe to release the connection, and then disconnect the fuel tank breather tube sub-assembly connector.

DISCONNECT FUEL TANK TO FILLER PIPE HOSE

Fig 6: Disconnecting Fuel Tank To Filler Pipe Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Loosen the hose clamp and disconnect the fuel tank to filler pipe hose from the fuel tank assembly.
REMOVE FUEL TANK ASSEMBLY

Fig 7: Identifying Fuel Tank Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 4 bolts and the fuel tank assembly from the vehicle.
2. Disengage the 2 hose clamps and remove the fuel tank main tube sub-assembly from the fuel tank assembly.
  
  Fig 8: Identifying Hose Clamps & The Fuel Tank Main Tube Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disengage the hose clamp and remove the fuel tank vent hose from the fuel tank assembly.
  
  Fig 9: Identifying Fuel Tank Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 FUEL TANK CUSHION

Fig 10: Identifying No. 2 Fuel Tank Cushions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 3 No. 2 fuel tank cushions from the fuel tank assembly.