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Fuel Tank ASSY: Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION  ) 
  2. DRAIN FUEL 
  3. REMOVE REAR SEAT CUSHION ASSY 
  4. REMOVE REAR FLOOR SERVICE HOLE COVER NO.2 
  5. REMOVE FUEL PUMP TUBE SUB-ASSY 
    NOTE:
    • Operation should be done under the condition that the remaining fuel is less than 1/4 in the tank. 
    • Check if there is any dirt like mud around the connector before this work and clean the dirt away. 
    • Be careful of dirt like mud because the quick connector has an O-ring to seal the pipe and the connector. 
    • Do not use any tool in this work. 
    • Do not bend or twist the nylon tube by force. 
    • After disconnecting the tube, cover the connector with a vinyl bag. 
    • When the connector and the pipe are stuck, pinch the tube between fingers, and tun it carefully to free and then disconnect the tube. 
      Fig 1: Removing Fuel Pump Tube Sub-Assy (1 Of 2)
      G00935561Courtesy 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.
    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.
        Fig 2: Removing Fuel Pump Tube Sub-Assy (2 Of 2)
        G00935562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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 with a vinyl bag or something after the connectors are disconnected.
  6. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the connector of the fuel sender gauge.
  7. REMOVE FRONT FLOOR BRACE CENTER (See  OVERHAUL  ) 
  8. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER RH 
  9. REMOVE RR SUSPENSION MEMBER BRACE REAR LOWER LH 
  10. REMOVE ENGINE UNDER COVER 
  11. REMOVE EXHAUST PIPE ASSY (See  REPLACEMENT  ) 
  12. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 
    1. Remove the 2 bolts and the propeller shaft heat insulator.
  13. REMOVE PROPELLER SHAFT ASSY (see  OVERHAUL  ) 
  14. REMOVE PARKING BRAKE CABLE ASSY NO.2 
  15. REMOVE PARKING BRAKE CABLE ASSY NO.3 
  16. SEPARATE FUEL TANK TO FILLER PIPE HOSE 
  17. SEPARATE BREATER TUBE FUEL HOSE 
  18. SEPARATE FUEL HOSE SUB-ASSY NO.3 
  19. SEPARATE FUEL TANK VENT HOSE 
  20. SEPARATE FUEL CUT OFF W/TUBE VALVE ASSY 
  21. REMOVE FUEL TANK ASSY 
    1. Using a mission jack, support the fuel tank assembly.
    2. Disconnect the fuel tank band No. 1 and remove the fuel tank assembly.
  22. REMOVE FUEL TANK VENT TUBE SET PLATE 
    1. Remove the 8 bolts and fuel tank vent tube set plate.
  23. REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    1. Lift up the fuel pump and sender gauge assembly, and disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge assembly and gasket.
      CAUTION:
      • Do not damage the fuel pump filter. 
      • Be careful that the arm of the sender gauge should not bent. 
        Fig 3: Identifying Fuel Sub-Section Hose
        G00935563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL SENDER GAGE ASSY 
  25. REMOVE FUEL TANK PROTECTOR SUB-ASSY NO.1 
  26. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY 
    NOTE:
    • Proper operations must be done in order to secure the sealing performance of the check valve, because the check valve is made of resin and it easily gets damaged by a forcible installation and removal operation. 
    • Be sure to exchange the check valve and the gasket with new ones. 
    1. Insert a clip remover between the check valve and the gasket and remove the check valve assembly, pulling up the valve little by little.
      Fig 4: Removing Fuel Tank Over Fill Check Valve Assy
      G00935564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY 
    1. Install a new gasket to the fuel tank.
    2. Apply some gasoline to the overall circumference of a new over fill check valve, and insert it, without any excessive force, taking care not to drop the gasket into the tank.
    3. Confirm that the over fill check valve is properly inserted without any clearance between the gasket and the lower surface of the valve.
  28. INSTALL FUEL TANK CUSHION NO.1 
    1. Attach the fuel tank cushion in the illustrated position.
      Fig 5: Identifying Position Of Attaching Fuel Tank Cushion
      G00935565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL FUEL TANK PROTECTOR SUB-ASSY NO.1 
  30. INSTALL FUEL SENDER GAGE ASSY 
    1. Inserting a new gasket in between, install the fuel sender gauge.

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

  31. 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 assembly to the fuel tank.
      Fig 6: Identifying Fuel Sub-Section Hose
      G00935566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. 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) 

  33. 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) 

  34. INSTALL FUEL CUT OFF W/TUBE VALVE ASSY 
  35. INSTALL FUEL TANK VENT HOSE 
  36. INSTALL FUEL HOSE SUB-ASSY NO.3 
  37. INSTALL BREATER TUBE FUEL HOSE 
  38. INSTALL FUEL TANK TO FILLER PIPE HOSE 
  39. INSTALL PARKING BRAKE CABLE ASSY NO.3 
  40. INSTALL PARKING BRAKE CABLE ASSY NO.2 
  41. INSTALL PROPELLER SHAFT ASSY (See  OVERHAUL  ) 
  42. 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) 

  43. INSTALL EXHAUST PIPE ASSY (See  REPLACEMENT  ) 
  44. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER LH 

    Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 

  45. INSTALL RR SUSPENSION MEMBER BRACE REAR LOWER RH 

    Torque: 20 N.m (200 kgf.cm, 15 ft.lbf) 

  46. INSTALL FRONT FLOOR BRACE CENTER (See  OVERHAUL  ) 
  47. INSTALL REAR FLOOR SERVICE HOLE COVER 
  48. INSTALL FUEL PUMP TUBE SUB-ASSY 
    1. Connect the connector in 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 in 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.
        Fig 7: Installing Fuel Pump Tube Sub-Assy
        G00935567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there is no damage and no foreign objects stuck in the connector connecting part. 
      • After the connection, confirm that they are securely connected, by pulling the connector and the pipe. 
  49. INSTALL REAR FLOOR SERVICE HOLE COVER NO.2 
  50. INSTALL REAR SEAT CUSHION ASSY 
  51. ADD FUEL 
  52. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS 
  53. CHECK EXHAUST GAS LEAK 
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