Fuel Tank ASSY (3MZ-FE): Replacement

1. Remove the 2 bolts and support bracket.

Fig 1: Removing Support Bracket

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1. Remove the 2 clips and unfasten the claw, and remove the tube protector.

Fig 2: Removing Tube Protector

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1. Remove the 4 nuts and fuel tank protector.

Fig 3: Removing Fuel Tank Protector

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1. Remove the 3 clips (*1), 6 nuts and tank protector.

Fig 4: Removing Clips, Nuts And Tank Protector

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1. Disconnect the fuel pump tube.
   1. Pinch the projection of the retainer to remove the lock claws and pull down it as shown in the illustration.
   2. Pull out the fuel pump tube.
   Fig 5: Disconnecting Fuel Pump Tube

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   NOTE:

   • Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
   • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
   • Do not use any tool in this operation.
   • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
   • When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
   Fig 6: Identifying Quick Connector

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2. Disconnect the fuel tank vent hose hose.
   1. Push the connector deep into the charcoal canister to release the locking tab.
   2. Pinch portion A.
   3. Pull out the connector.
   Fig 7: Disconnecting Fuel Tank Vent Hose

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3. Disconnect the fuel tank breather tube No.3.
   1. Lower the connector checker slightly.
   2. Pinch the tube connector.
   3. Pull out the breather tube.
   Fig 8: Disconnecting Fuel Tank Breather Tube No. 3

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   NOTE:

   • Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
   • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
   • Do not use any tool in this operation.
   • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
   • When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
   Fig 9: Identifying Tube Connector

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4. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
   Fig 10: Disconnecting Fuel Tank To Filler Pipe Hose

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5. Disconnect the fuel tank wire connector.
6. Remove the connector clamp.
7. Set up a transmission jack under the fuel tank.
8. Remove the 4 bolts and 2 fuel tank bands.
9. Remove the 2 nuts.
10. Operate the transmission jack and remove the fuel tank.

Fig 11: Removing Fuel Tank Bands

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1. Unfasten the 2 claws and remove the tube.

Fig 12: Removing Tube

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1. Loosen the hose clamp bolt and remove the hose.

Fig 13: Loosening Hose Clamp Bolt

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1. Disconnect the vapor pressure sensor connector.
2. Unfasten the 4 claws and remove the wire.

Fig 14: Removing Wire

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1. Remove the tube joint clip.
2. Pull out the vapor pressure sensor.

Fig 15: Removing Tube Joint Clip

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1. Push the connector deep into the charcoal canister to release the locking tab.
2. Pinch portion A.
3. Pull out the connector.
4. Unfasten the claw and remove the vent hose.

Fig 16: Removing Vent Hose

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1. Remove the tube support from the fuel tank.

Fig 17: Removing Tube Support From Fuel Tank

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1. Remove the bolt and nut, and then remove the fuel tank side plate and the fuel tank bracket.

Fig 18: Removing Fuel Tank Side Plate And Fuel Tank Bracket

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1. Remove the cushion set and cushion No. 5.

Fig 19: Removing Cushion Set And Cushion No. 5

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Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) 

1. Install a new tube support as shown in the illustration.

Fig 20: Installing Tube Support

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1. Push and hold down the vapor pressure sensor.
2. Install the fuel tube joint clip to the sensor.
   NOTE:

   • Check that there are no scratches or foreign objects on the connecting parts.
   • Check that the fuel tube joint is fully inserted.
   • Check that the fuel tube joint clip is on the collar of the fuel tube joint.
     Fig 21: Installing Fuel Tube Joint Clip To Sensor

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • After installing the tube joint clip, check if the fuel joint is securely connected by trying to pull it.

1. Set up the fuel tank to the transmission jack.
2. Operate the transmission jack and install the fuel tank.
3. Tighten the 2 nuts.

   Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

4. Install the 2 fuel tank bands with the 4 bolts.

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

5. Install the connector clamp.
6. Connect the fuel tank wire connector.
7. Connect the fuel tank to filler pipe hose.
8. Connect the fuel tank breather tube No. 3.
   1. Push the quick connector to the pipe until it makes "click" sound.
      Fig 22: Connecting Fuel Tank Wire Connector

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      NOTE:

      • Check if there is any damage or foreign objects on the connected part.
      • After connecting, check if the quick connector and the pipe are securely connected by trying to pull them apart.
   2. Return the connector checker to its original position.
9. Connect the fuel tank vent hose.
10. Connect the fuel pump tube.
    1. Push the quick connector in the direction of the white arrow.
       Fig 23: Connecting Fuel Pump Tube

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       NOTE:

       • Check if there is any damage or foreign objects on the connected part.
       • After connecting, check if the quick connector and the pipe are securely connected by trying to pull them.
    2. Push up on the retainer until the claws lock.

1. Install the tank protector with the 6 nuts.

   Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 

2. Install 3 new clips.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 

Torque: 22 N.m (224 kgf.cm, 16 ft.lbf)