Fuel Tank: Removal

DISCHARGE FUEL SYSTEM PRESSURE
HINT:

(See PRECAUTION ).
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
REMOVE REAR SEAT CUSHION ASSEMBLY (See REMOVAL )
REMOVE REAR FLOOR SERVICE HOLE COVER (See REMOVAL )
SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See REMOVAL )
REMOVE FUEL TANK VENT TUBE SET PLATE (See REMOVAL )
REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See REMOVAL )
DRAIN FUEL
REMOVE EXHAUST PIPE ASSEMBLY CENTER (See REMOVAL )
DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO. 2
1. Remove the set bolt and set nut of the parking brake cable assembly No. 2.
  
  Fig 1: Locating Parking Brake Cable Assembly No. 2 Bolt And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO. 3
1. Remove the set bolt and set nut of the parking brake cable assembly No. 3.
  
  Fig 2: Locating Parking Brake Cable Assembly No. 3 Bolt And Set Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK PROTECTOR LOWER CENTER
1. Remove the 4 bolts and fuel tank protector.
  
  Fig 3: Locating Fuel Tank Protector Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK ASSEMBLY
1. Disconnect the fuel pump tube.
  1. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.
  2. Pull out the fuel tank main tube.
    
    Fig 4: Pinching Tabs Of Retainer
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
    
    It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
    
    Do not use any tools in this operation.
    
    Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
    
    When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
2. Disconnect the fuel tube No. 1.
  1. Pinch the tube connector and then pull out the fuel tube No.1.
    NOTE:
    Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
    
    It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
    
    Do not use any tools in this operation.
    
    Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
    
    When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
    
    Fig 5: Pinching Tube Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set up a transmission jack underneath the fuel tank.
4. Remove the 2 set bolts of the fuel tank bands.
5. Remove the hose clamp and disconnect the fuel tank to filter pipe hose.
6. Disconnect the fuel tank vent hose from the charcoal canister.
  1. Push the connector deep into the charcoal canister to release the locking pin.
  2. Pinch portion A.
  3. Pull out the connector.
7. Remove the fuel tank.
  
  Fig 6: Locating Fuel Tank Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
  
  Fig 7: Locating Fuel Tank Bands And Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the 4 clip nuts.
  
  Fig 8: Locating Clip Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002