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Fuel Tank: Removal

  1. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. REMOVE REAR SEAT CUSHION ASSEMBLY RH (See  REMOVAL   ) 
  3. REMOVE REAR FLOOR SERVICE HOLE COVER (See  REMOVAL   ) 
  4. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (See  REMOVAL   ) 
  5. DRAIN FUEL 
  6. REMOVE REAR CONSOLE BOX ASSEMBLY (See  REMOVAL  ) 
  7. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    1. Using a clip remover, remove the clip [A].
    2. Pull off the floor carpet front [B].
      Fig 1: Pulling Off Floor Carpet Front
      G04462079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the heated oxygen sensor connector [C].
    4. Remove the grommet, then pull the connector to the outside of the vehicle [D].
      Fig 2: Disconnecting Heated Oxygen Sensor Connector
      G04462080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the heated oxygen sensor connector [E].
    6. Remove the grommet, then pull the connector to the outside of the vehicle [F].
      Fig 3: Disconnecting Heated Oxygen Sensor Connector
      G04462081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove 2 nuts and the floor panel brace front [G].
    8. Remove the 4 bolts and 4 compression springs [H].
    9. Remove the exhaust pipe front from the 2 exhaust pipe supports No. 4 [I].
      Fig 4: Removing Nuts From Floor Panel Brace Front
      G04462082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 5: Identifying Bolts On Compression Springs And Exhaust Pipe Supports No. 4
      G04462083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the gasket from the exhaust manifold [J].
      Fig 6: Removing Gasket From Exhaust Manifold
      G04462084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the gasket from the exhaust pipe front [K].
      Fig 7: Removing Gasket From Exhaust Pipe Front
      G04462085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 FUEL TANK PROTECTOR 
    1. Remove the 4 bolts, then remove the No. 1 fuel tank protector.
      Fig 8: Removing Bolts From No. 1 Fuel Tank Protector
      G04462086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 bolts, then disconnect the No. 2 parking brake cable.
      Fig 9: Removing Bolts For Disconnecting No. 2 Parking Brake Cable Assembly
      G04462087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 bolts, then disconnect the No. 3 parking brake cable.
      Fig 10: Removing Bolts For Disconnecting No. 3 Parking Brake Cable Assembly
      G04462088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel tank main tube.
      1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and push it down as shown in the illustration.
      2. Pull the fuel tank main tube out of the pipe.
        NOTE:
        • Remove any dirt or 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 the O-ring that seals the pipe.
          Fig 11: Disconnecting Fuel Tank Main Tube
          G04462089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • 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 vinyl bag after disconnecting the fuel tank main tube.
        • If the fuel tube connector and pipe are stuck, push and pull them to release.
    2. Disconnect the fuel tank breather tube.
      1. Remove the checker of the fuel tube connector from the pipe.
      2. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
        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 the O-ring that seals the pipe.
          Fig 12: Disconnecting Fuel Tank Breather Tube
          G04462090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • 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 vinyl bag after disconnecting the fuel tank breather tube.
        • If the fuel tube connector and pipe are stuck, push and pull to release them.
    3. Disconnect the fuel tank vent hose.
      1. Pinch the tab of the retainer of the fuel tube connector to remove the lock claws and slide it as shown in the illustration.
      2. Pull the fuel tank vent hose out of the pipe.
        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 the O-ring that seals the plug.
          Fig 13: Disconnecting Fuel Tank Vent Hose
          G04462091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • 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 vinyl bag after disconnecting the fuel tank vent hose.
    4. Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.
      Fig 14: Unfastening Claw
      G04462092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Loosen the hose clamp bolt, then disconnect the fuel tank filler pipe hose from the fuel tank.
      Fig 15: Loosening Hose Clamp Bolt
      G04462093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Hold the fuel tank using a transmission jack.
    7. Remove the 4 bolts, then remove the 2 fuel tank bands No. 1 [G].
    8. Operate the transmission jack, then remove the fuel tank.
      Fig 16: Locating Bolts For Removing Fuel Tank Bands No. 1
      G04462094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the fuel tank main tube from the fuel tank.
      Fig 17: Removing Fuel Tank Main Tube From Fuel Tank
      G04462095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK VENT HOSE 
    1. Remove the fuel vent hose from the fuel tank clamp.
      Fig 18: Removing Fuel Vent Hose From Fuel Tank Clamp
      G04462096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 1 FUEL TANK CUSHION 
    1. Remove the 4 fuel tank cushions No. 1 from the fuel tank.
      Fig 19: Removing Fuel Tank Cushions No. 1 From Fuel Tank
      G04462097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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