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Fuel Tank: Removal

  1. PRECAUTION  (See REMOVAL  )
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (see PRECAUTION  ).
  3. REMOVE COWL TOP VENTILATOR LOUVER RH  (See REMOVAL )
  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
    NOTE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
  5. REMOVE REAR SEAT ASSEMBLY (for Power Seat) 
    1. Remove the rear seat assembly (see REMOVAL ).
  6. REMOVE REAR SEAT ASSEMBLY (for Ottoman) 
    1. Remove the rear seat assembly (see REMOVAL ).
  7. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type) 
    1. Remove the rear seat cushion assembly (see REMOVAL ).
  8. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the connector from the fuel suction with pump and gauge tube assembly.
      Fig 1: Locating Fuel Pump Connector
      G04947835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL TANK MAIN AND RETURN TUBE 
    1. Disconnect the fuel main tube and fuel return tube.
      1. Remove the 2 tube joint clips and 2 fuel tubes.
        NOTE:
        • Remove any dirt and foreign matter on the fuel tube joint before performing this work.
        • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
        • 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 plastic bag and tape after disconnecting the fuel tubes.
          Fig 2: Disconnecting Fuel Main Tube And Fuel Return Tube
          G04947943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the fuel sender gauge connector.
      2. Fig 3: Locating Fuel Sender Gauge Connector
      G04948090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    1. Remove the exhaust pipe (see REMOVAL ).
  12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 
    1. Remove the propeller with center bearing shaft (see REMOVAL ).
  13. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel main tube.
      NOTE:
      • Check for any dirt and foreign matter 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 to separate the pipe and connector.
      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
        Fig 4: Disconnecting Fuel Main Tube
        G04948091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
    2. Disconnect the fuel return tube.
      NOTE:
      • Check for any dirt and foreign matter 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 to separate the pipe and connector.
      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel return tube.
      • If the pipe and connector are stuck together, pinch the vent tube between your fingers and turn it carefully to free it. Then disconnect the fuel return tube.
        Fig 5: Disconnecting Fuel Main Tube
        G04948091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Loosen the clamp and disconnect the filler pipe hose.
      Fig 6: Locating Filler Pipe Hose Clamp
      G04948093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place a mission jack under the fuel tank.
    5. Remove the 4 bolts and 2 fuel tank bands.
      6. Fig 7: Locating Fuel Tank Bands Bolts
      G04948094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Lower the mission jack so that the fuel tank breather tube can be disconnected.
      NOTE: Make sure that no load is applied to the fuel filler pipe.

      HINT:

      Lower the mission jack slowly.

    7. Disconnect the fuel tank breather tube sub-assembly.
      NOTE:
      • Check for any dirt and foreign matter 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 to separate the pipe and connector.
      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the breather tube.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the breather tube.
        Fig 8: Disconnecting Fuel Tank Breather Tube Sub-Assembly
        G04948095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the fuel tank vent hose sub-assembly.
      1. Pinch the retainer and then raise it.
        NOTE:
        • Check for any dirt and foreign matter 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 to separate the pipe and connector.
        • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the vent hose contains the O-rings that seal the plug.
        • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the vent hose.
        • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.
          Fig 9: Disconnecting Fuel Tank Vent Hose Sub-Assembly
          G04948096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Lower the mission jack to remove the fuel tank from the vehicle.
      NOTE:
      • Do not allow the fuel tank to contact the vehicle, especially the differential.
      • Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.

      HINT:

      Lower the mission jack slowly.

  14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Remove the 8 bolts and fuel vent tube set plate.
      Fig 10: Locating Set Plate Bolts
      G04947944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel hose.
      3. Fig 11: Locating Fuel Hose Clamp
      G04947945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel suction with pump and gauge tube from the fuel tank.
      NOTE:
      • Make sure that the sender gauge arm does not bend.
      • Do not damage the fuel suction tube with pump and gauge.
    4. Remove the gasket.
  15. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Remove the 5 screws and fuel sender gauge.
      2. Fig 12: Locating Fuel Sender Gauge Screws
      G04948099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket.
  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the 6 clamps and fuel tank main tube from the fuel tank.
      Fig 13: Locating Fuel Tank Main Tube Clamps
      G04948100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel hose clamp.
      Fig 14: Identifying Fuel Hose Clamp
      G04948101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO.2 FUEL TANK PROTECTOR 
    1. Remove the bolt and clip and fuel tank protector from the fuel tank.
      2. Fig 15: Identifying Fuel Tank Protector Bolt And Clip
      G04948102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamp from the fuel tank.
  18. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose sub-assembly.
      Fig 16: Disconnecting Fuel Tank Vent Hose Sub-Assembly
      G04948103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matter 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 to separate the pipe and connector.
      • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the vent hose.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.
  19. REMOVE FUEL TANK CUSHION 
    1. Remove the 3 tank cushions.
      Fig 17: Identifying Fuel Tank Cushion
      G04948104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the tank protector and 5 tank cushions.
      Fig 18: Identifying Tank Protector And Tank Cushions
      G04948105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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