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Fuel Tank ASSY: Replacement

CAUTION:
  • Always use new gaskets when replacing the fuel tank or component parts.
  • Apply the proper torque.
  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION  ) 
  2. DRAIN FUEL (See  PRECAUTION  ) 
  3. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR SEAT) (See  OVERHAUL  ) 
  4. REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See  OVERHAUL  ) 
  5. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2 (See  REPLACEMENT  ) 
  6. REMOVE FUEL TANK MAIN TUBE SUB-ASSY 
    NOTE:
    • These procedures should be performed with the fuel tank less than 1/4 full.
    • Check for dirt contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
    • Do not use any tools in these procedures.
    • Do not forcefully bend or twist the nylon tube.
    • Check for dirt contamination on the pipe seal surface. Clean if necessary.
    • Put the pipe and connector ends in vinyl bags to prevent damage and dirt contamination.
    • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
    Fig 1: Disconnecting connector in fuel tank side
    G01051880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the connector in the fuel tank side.
      1. Remove the tube joint clip.
      2. Pull out the fuel main tube.
      3. Plug the port of the fuel suction plate with a clean rubber cap.
        Fig 2: Disconnecting Connector In Fuel Tank Side
        G01051881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector in the fuel pipe side.
      1. Clean the pipe before the operation.
      2. Pull out the connector, holding the claw of the retainer by thumb as shown in the illustration.
      NOTE: If the connector and the pipe are stuck together, release them by pushing and pulling them by hand.

      HINT:

      Do not remove the retainer when it is reinstalled.

    3. Protect each connecting part from damage and contamination by covering it with a vinyl bag.
  7. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the connector of the fuel sender gauge.
  8. REMOVE FRONT FLOOR BRACE CENTER (SEE  OVERHAUL  ) 
  9. REMOVE ENGINE UNDER COVER NO.2 
  10. REMOVE EXHAUST PIPE ASSY (SEE  REPLACEMENT  ) 
  11. REMOVE PROPELLER SHAFT HEAT INSULATOR 
  12. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 
    1. Remove the 2 bolts and the propeller shaft heat insulator.
  13. REMOVE DIFFERENTIAL SUPPORT PROTECTOR NO.1 
  14. REMOVE DIFFERENTIAL SUPPORT PROTECTOR NO.2 
  15. REMOVE PROPELLER SHAFT ASSY (SEE  OVERHAUL  ) 
  16. REMOVE PARKING BRAKE CABLE ASSY NO.2 (See  PARKING BRAKE  ) 
  17. REMOVE PARKING BRAKE CABLE ASSY NO.3 (See  PARKING BRAKE  ) 
  18. REMOVE FUEL TANK TO FILLER PIPE HOSE 
  19. REMOVE FUEL TANK EVAPORATION VENT TUBE 
  20. REMOVE FUEL TANK BREATHER HOSE 
  21. REMOVE FUEL TANK ASSY 
    1. Using a mission jack, support the fuel tank.
    2. Disconnect the fuel tank band No.1 and remove the fuel tank.
  22. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and fuel tank vent tube set plate.
      Fig 3: Disconnecting Fuel Sub-Suction Hose From Fuel Return Jet Tube
      G01051882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Lift up the fuel pump and sender gauge assy. Disconnect the fuel sub-suction hose from the fuel return jet tube, and remove the fuel pump, sender gauge assy and gasket.
    CAUTION:
    • Do not damage the fuel pump filter.
    • Be careful that the arm of the sender gauge should not bent.
  24. REMOVE FUEL SENDER GAGE ASSY 
  25. REMOVE FUEL TANK PROTECTOR SUB-ASSY NO.1 
  26. REMOVE FUEL TANK BREATHER TUBE SUB-ASSY 
  27. REMOVE CHECK VALVE PROTECTOR 
  28. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY 
    Fig 4: Removing Fuel Tank Over Fill Check Valve Assy
    G01051883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • When installing or removing the check valve, do not use force. The check valve is made of resin and damages easily. Following these procedures carefully ensures that the check valve stays in good condition and maintains its sealing properties.
    • Check valves and gaskets must be replaced with new ones.
    1. Insert a clip remover between the check valve and the gasket and remove the check valve assy, pulling up the valve little by little.
  29. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY 
    1. Install a new gasket to the fuel tank.
    2. Apply some gasoline to the entire circumference of a new over fill check valve, and insert it into the fuel tank without using excessive force. Take care not to drop the gasket into the tank.
    3. Confirm that the over fill check valve is inserted without any clearance between the gasket and the lower surface of the valve.
  30. INSTALL CHECK VALVE PROTECTOR 
  31. INSTALL FUEL TANK CUSHION NO.1 
    1. Attach the fuel tank cushions to the areas marked with diagonal lines in the illustration.
      Fig 5: Identifying Fuel Tank Cushions Installing Area
      G01051884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL FUEL TANK BREATHER TUBE SUB-ASSY 
  33. INSTALL FUEL TANK PROTECTOR SUB-ASSY NO.1 
  34. INSTALL FUEL SENDER GAGE ASSY 
    1. < a >Inserting a new gasket in between, install the fuel sender gauge.

      Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf) 

  35. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Install a new gasket to the fuel suction plate.
    2. Connect the fuel sub-suction hose to the fuel return jet tube.
    3. Attach the fuel pump and sender gauge assy to the fuel tank.
      Fig 6: Connecting Fuel Sub-Suction Hose To Fuel Return Jet Tube
      G01051885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the fuel tank vent tube set plate with the 8 bolts.

      Torque: 6.0 N.m (61 kgf.cm, 52 in. lbf) 

  37. INSTALL FUEL TANK ASSY 
    1. Install the fuel tank with the fuel tank band.

      Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 

  38. INSTALL FUEL TANK BREATHER hose 
  39. INSTALL FUEL TANK EVAPORATION VENT TUBE 
  40. INSTALL FUEL TANK TO FILLER PIPE HOSE 
  41. INSTALL PARKING BRAKE CABLE ASSY NO.3 (See  PARKING BRAKE  ) 
  42. INSTALL PARKING BRAKE CABLE ASSY NO.2 (See  PARKING BRAKE  ) 
  43. INSTALL PROPELLER SHAFT ASSY (SEE  OVERHAUL  ) 
  44. INSTALL DIFFERENTIAL SUPPORT PROTECTOR NO.2 
  45. INSTALL DIFFERENTIAL SUPPORT PROTECTOR NO.1 
  46. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 
    1. Install the front floor heat insulator with the 4 bolts.

      Torque: 5.4 N.m (55 kgf.cm, 47 in. lbf) 

  47. INSTALL PROPELLER SHAFT HEAT INSULATOR 
  48. INSTALL EXHAUST PIPE ASSY (SEE  REPLACEMENT  ) 
  49. INSTALL ENGINE UNDER COVER NO.2 
  50. INSTALL FRONT FLOOR BRACE CENTER (SEE  OVERHAUL  ) 
  51. INSTALL REAR FLOOR SERVICE HOLE COVER 
    Fig 7: Installing Fuel Tube Connector
    G01051886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL FUEL TANK MAIN TUBE SUB-ASSY 
    1. Connect the connector on the fuel tank side.
      1. Attach the fuel tube connector to the port of the fuel suction plate.
      2. Install the tube joint clip.
    2. Connect the connector on the fuel pipe side.
    1. Insert the connector by aligning the axes of the pipe and the connector until the retainer makes a click sound.
    NOTE:
    • Check for damage and dirt contamination in the pipe and around the connector.
    • After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.
  53. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2 (See  REPLACEMENT  ) 
  54. INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See  OVERHAUL  ) 
  55. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR SEAT) (See  OVERHAUL  ) 
  56. ADD FUEL (See  PRECAUTION  ) 
  57. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  58. CHECK FOR EXHAUST GAS LEAKS (SEE  REPLACEMENT  ) 
  59. POWER WINDOW CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
  60. FRONT POWER SEAT CONTROL SYSTEM INITIALIZE (See  INITIALIZATION  ) 
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