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Fuel Tank: Removal: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge the fuel system pressure. Refer to PRECAUTION .
  2. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (for Automatic Transmission) 
    1. Remove the 2 nuts and the fuel tank protector bracket.
      Fig 1: Identifying Fuel Tank Protector Bracket Nuts (A/T)
      GTY192697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and the fuel tank protector.
      Fig 2: Identifying Fuel Tank Protector Nuts
      GTY309751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (for Manual Transmission) 
    1. Remove the nut and the fuel tank protector bracket.
      Fig 3: Identifying Fuel Tank Protector Bracket Nut (M/T)
      GTY192728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and the fuel tank protector.
      Fig 4: Identifying Fuel Tank Protector Nuts
      GTY309751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Pinch the retainer to disengage the lock claws and pull out the fuel tank main tube.
      Fig 5: Identifying Fuel Tank Main Tube Sub-Assembly
      GTY172350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 O-Ring
      *a Lock
      *b Unlock
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube.
      • To protect the tube, cover it with a vinyl bag after disconnecting it.
      • When the connector and the pipe are stuck, turn the retainer carefully to disconnect them.
  5. DRAIN FUEL 
    1. Operate the fuel pump and drain the fuel from the fuel tank through the fuel tank main tube. Refer to ON-VEHICLE INSPECTION - Step 1 .
  6. REMOVE FRONT DOOR SCUFF PLATE LH 
    1. Disengage the 14 claws and remove the front door scuff plate.
      Fig 6: Identifying Front Door Scuff Plate Claws
      GTY192497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE REAR DOOR SCUFF PLATE LH 
    1. Disengage the 6 claws and remove the rear door scuff plate.
      Fig 7: Identifying Rear Door Scuff Plate Claws
      GTY184338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE REAR SEAT CUSHION ASSEMBLY LH 
    1. Remove the 2 bolts, then remove the rear seat cushion LH.
      Fig 8: Identifying Floor Carpet
      GTY169599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Pull back the floor carpet.
      Fig 9: Identifying Center Floor Silencer Pad LH
      GTY192484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the center floor silencer pad LH.
    3. Remove the 3 screws from the center floor.
      Fig 10: Identifying Center Floor Screws
      GTY186965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the connector.
      Fig 11: Identifying Connector
      GTY186966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the clamp bolt, and disconnect the fuel tank to filler pipe hose.
      Fig 12: Identifying Clamp Bolt
      GTY167914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Turn the retainer to disengage the lock claws and pull out the fuel tank breather tube.
      Fig 13: Identifying Fuel Tank Breather Tube Sub-Assembly And Retainer
      GTY179551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 O-Ring
      Turn
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube.
      • To protect the tube, cover it with a vinyl bag after disconnecting it.
      • When the connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the fuel tank tube.
  12. DISCONNECT FUEL TANK RETURN TUBE 
    1. Pinch the retainer to disengage the lock claws and pull out the fuel tank return tube.
      Fig 14: Identifying Fuel Tank Return Tube And Lock Claws
      GTY167995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 O-Ring
      *a Lock
      *b Unlock
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube.
      • To protect the tube, cover it with a vinyl bag after disconnecting it.
      • When the connector and the pipe are stuck, turn the retainer carefully to disconnect them.
  13. DISCONNECT FUEL TANK VENT HOSE 
    1. Disconnect the fuel tank breather tube from the fuel tank.
      Fig 15: Identifying Fuel Tank Breather Tube
      GTY183144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Pinch
      Push
      1. Push the connector deep inside.
      2. Pinch portion A, as shown in the illustration.
      3. Pull out the connector.
  14. REMOVE FUEL TANK ASSEMBLY 
    1. Hold the fuel tank using a mission jack.
      Fig 16: Identifying Fuel Tank Bands
      GTY169594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 fuel tank bands.
      1. Remove the 2 bolts.
      2. Remove the 2 clips and 2 pins, then remove the 2 fuel tank bands.
  15. REMOVE NO. 3 FUEL TANK PROTECTOR 
    1. Remove the 2 bolts and disengage the 3 claws, then remove the No. 3 fuel tank protector.
      Fig 17: Identifying Fuel Tank Protector Bolts
      GTY169632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL TANK CUSHION 
    1. Remove the 4 fuel tank cushions from the fuel tank.
      Fig 18: Identifying Fuel Tank Cushions & Fuel Tank
      GTY192486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Remove the 2 joint clips, and pull out the 2 fuel tank tubes.
      Fig 19: Identifying Joint Clips And Fuel Tank Tubes
      GTY176892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-Ring
      Pull
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube by force.
      • After disconnecting, cover the fuel tube joint with a vinyl bag.
      • When the fuel tube joint and fuel suction plate are stuck, turn the fuel tank main tube carefully to free and then disconnect it. Likewise, disconnect the fuel tank return tube.
  18. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  See step  2
  19. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Pinch the retainer to disengage the lock claws and pull out the fuel tank breather tube.
      Fig 20: Identifying Fuel Tank Breather Tube Sub-Assembly And Lock Claws
      GTY190247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 O-Ring
      Turn
      Pull
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube.
      • To protect the tube, cover it with a vinyl bag after disconnecting it.
      • When the connector and the pipe are stuck, turn the fuel tank breather tube carefully to disconnect them.
  20. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the clamp bolt, and disconnect the fuel tank to filler pipe hose.
      Fig 21: Identifying Fuel Tank To Filler Pipe Hose With Clamp
      GTY192727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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