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Removal & Installation

  1. REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY (See  REMOVAL & INSTALLATION   ) 
  2. REMOVE REAR FLOOR SERVICE HOLE COVER (See  REMOVAL & INSTALLATION   ) 
  3. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
    1. Start the engine.
    2. After the engine has stopped on the its own, turn the ignition switch to lock.
  4. REMOVE FUEL TANK PROTECTOR No. 2 (See  REMOVAL & INSTALLATION    ) 
  5. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY (See  REMOVAL & INSTALLATION   ) 
  6. REMOVE FUEL TANK VENT TUBE SET PLATE (See  REMOVAL & INSTALLATION   ) 
  7. REMOVE FUEL PUMP ASSEMBLY (See  REMOVAL & INSTALLATION   ) 
  8. REMOVE FUEL SUCTION TUBE SET GASKET (See  REMOVAL & INSTALLATION   ) 
  9. DRAIN FUEL 
  10. REMOVE FRONT DOOR SCUFF PLATE RH 
  11. REMOVE COWL SIDE TRIM BOARD RH 
  12. REMOVE REAR DOOR SCUFF PLATE RH 
  13. REMOVE CENTER PILLAR GARNISH LOWER RH 
  14. REMOVE FRONT SEAT ASSY RH (See OVERHAUL  ) 
  15. REMOVE EXHAUST PIPE ASSY CENTER 
    Fig 1: Removing Exhaust Pipe Center Assy
    G00922844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the oxygen sensor connector.
    2. Remove the 2 exhaust pipe support.
    3. Remove the bolt and clamp.
    4. Remove the 2 bolts, 2 compression springs and exhaust pipe.
  16. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (See  OVERHAUL  ) 
  17. REMOVE FRONT FLOOR HEAT INSULATOR No. 1 
    Fig 2: Removing Front Floor Heat Insulator No. 1
    G00922845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 nuts and front floor heat insulator.
  18. REMOVE FRONT FLOOR HEAT INSULATOR No. 2 
    Fig 3: Removing Front Floor Heat Insulator No. 2
    G00922846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 nuts and front floor heat insulator.
  19. SEPARATE PARKING BRAKE CABLE ASSY No. 2 
    Fig 4: Separating Parking Brake Cable Assy No. 2
    G00922847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 installing bolts of the parking brake cable.
  20. SEPARATE PARKING BRAKE CABLE ASSY No. 3  
    Fig 5: Separating Parking Brake Cable Assy No. 3
    G00922848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 installing bolts of the parking brake cable.
  21. DISCONNECT CHARCOAL CANISTER OUTLET HOSE No. 1 
    Fig 6: Disconnecting Charcoal Canister Outlet Hose
    G00922849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the charcoal canister outlet hose from the charcoal canister.
  22. DISCONNECT FUEL TANK TO CANISTER TUBE 
    Fig 7: Disconnecting Fuel Tank To Canister Tube
    G00922850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank to canister tube from the charcoal canister.
    2. Remove the fuel tank to canister tube from the 2 evaporation vent tube clamps.
  23. DISCONNECT FUEL EMISSION TUBE No. 2 
    Fig 8: Disconnecting Fuel Emission Tube No. 2
    G00922851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel emission tube from the charcoal canister.
    2. Remove the fuel tank to canister tube from the 2 evaporation vent tube clamps.
  24. DISCONNECT FUEL EVAPORATION TUBE SUB-ASSY No. 1 
    Fig 9: Disconnecting Fuel Evaporation Tube Sub-Assy No. 1
    G00922852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pinch the fuel tube connector clip and then pull out the fuel evaporation tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube connector with a vinyl bag.
    • When the fuel tube connector and pipe are stuck, pinch the fuel evaporation tube between fingers, and turn it carefully to free and then disconnect the fuel evaporation tube.
    Fig 10: Disconnecting Fuel Tube Connector
    G00922853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FUEL TANK VENT HOSE 
    Fig 11: Disconnecting Fuel Tank Vent Hose
    G00922854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank bent hose from the charcoal canister.
      1. Push the connector deep inside.
      2. Pinch portion A.
      3. Pull out the connector.
  26. REMOVE CHARCOAL CANISTER ASSY 
    Fig 12: Removing Charcoal Canister Assy
    G00922855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the pressure switching valve connector.
    2. Remove the 3 bolts and charcoal canister.
  27. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    Fig 13: Disconnecting Fuel Tank Main Tube Sub-Assy
    G00922856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pinch the fuel tube connector clip, and remove the fuel tube connector clip.
    2. Pull out the fuel tank main tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean the dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the connector with a vinyl bag.
    • When the fuel tube connector and pipe are stuck, pinch the fuel tank main tube between fingers, and turn it carefully to free and then disconnect the fuel tank main tube.
    Fig 14: Disconnecting Fuel Tube Connector
    G00922857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT FUEL TANK INLET PIPE FUEL HOSE 
    Fig 15: Disconnecting Fuel Tank Inlet Pipe Fuel Hose
    G00922858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank inlet pipe fuel hose from the fuel tank.
  29. REMOVE FUEL TANK ASSY 
      Fig 16: Removing Fuel Tank Assy
      G00922859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Set a mission jack top the fuel tank.
    2. Remove the 4 bolts and 2 fuel tank bands.
    3. Operate the mission jack and then disconnect the 2 fuel tank breather hoses.
  30. REMOVE FUEL TANK MAIN TUBE SUB-ASSY 
    1. Remove the fuel tank main tube from the fuel tube clamp.
      Fig 17: Removing Fuel Tank Main Tube From Fuel Tube Clamp
      G00922860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FUEL TUBE CLAMP No. 4 
    Fig 18: Removing Fuel Tube Clamp No. 4
    G00922861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and fuel tube clamp.
  32. REMOVE FUEL TANK BREATHER HOSE 
    Fig 19: Removing Fuel Tank Breather Hose
    G00922862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the fuel breather hose from the fuel tank.
  33. REMOVE FUEL EMISSION TUBE SUB-ASSY No. 1 
    Fig 20: Removing Fuel Emission Tube Sub-Assy No. 1
    G00922863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pinch the fuel tube connector clip and then pull out the fuel emission tube.
    NOTE:
    • Check if there is any dirt like mud around the fuel tube connector before this work and clean dirt away.
    • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
    • Do not use any tool in this work.
    • Do not bend or twist the nylon tube by force.
    • After disconnecting, cover the fuel tube connector with a vinyl bag.
    • When the fuel tube connector and pipe are stuck, pinch the fuel emission tube between fingers, and turn it carefully to free and then disconnect the fuel emission tube.
      • Fig 21: Disconnecting Fuel Emission Tube
      G00922864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE EVAPORATION VENT TUBE CLAMP No. 2 
    1. Remove the bolt and evaporation vent tube clamp.
      2. Fig 22: Removing Evaporation Vent Tube Clamp
      G00922865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CHECK VALVE PROTECTOR 
    Fig 23: Removing Check Valve Protector
    G00922866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and check valve protector.
  36. REMOVE BREATHER TUBE SUB-ASSY 
    Fig 24: Removing Breather Tube Sub-Assy
    G00922867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pinch the fuel tube connector clip and then pull out the breather tube.
      NOTE:
      • Check if there is any dirt like mud around the connector before this work and clean dirt away. 
      • Be careful of dirt like mud because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe. 
      • Do not use any tool in this work. 
      • Do not bend or twist the nylon tube by force. 
      • After disconnecting, cover the connector with a vinyl bag. 
      • When the fuel tube connector and pipe are stuck, pinch the tube between fingers, and turn it carefully to free and then disconnect the tube. 
        • Fig 25: Disconnecting Fuel Tube Connector
        G00922868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the breather tube from the Fuel tube bracket and clamp.
  37. REMOVE FUEL TUBE BRACKET 
    Fig 26: Removing Fuel Tube Bracket
    G00922869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the fuel tube bracket from the fuel tank.
  38. REMOVE FUEL TUBE CLAMP No. 2 
    Fig 27: Removing Fuel Tube Clamp No. 2
    G00922870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the fuel tube clamp from the fuel tank.
  39. REMOVE FUEL TANK VENT HOSE 
    Fig 28: Removing Fuel Tank Vent Hose
    G00922871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank bent hose from the charcoal canister.
      1. Push the connector deep inside.
      2. Pinch portion A.
      3. Pull out the connector.
    2. Remove the fuel tank vent hose from the fuel tube clamp.
  40. REMOVE FUEL TUBE CLAMP No. 4 
    Fig 29: Removing Fuel Tube Clamp No. 4
    G00922872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and fuel tube clamp.
  41. REMOVE FUEL TANK INLET VALVE ASSY 
    Fig 30: Removing Fuel Tank Inlet Valve Assy
    G00922873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolt, check valve support and fuel tank inlet valve.
  42. REMOVE CHECK VALVE GASKET 
    Fig 31: Removing Check Valve Gasket
    G00922874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the gasket from the fuel tank inlet valve.
  43. REMOVE FUEL TANK PROTECTOR No. 1 
    1. Using a drill, cut the flange portion of the rivet.
      Fig 32: Cutting Flange Portion Of Rivet Using Drill
      G00922875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Wind tape so that the drill blade appears approx. 5.0 mm (0.197 in.) on the edge.
    NOTE:
    • If the drill is pressed too firmly, the rivet will also rotate with the drill edge, thus flange will not be cut.
    • If the drill is pried against the rivet, the installation hole of the rivet may be cut or the drill blade may be damaged.
    • Use caution against the hot rivet after cut.
  44. REMOVE FUEL TANK CUSHION No. 1 
    Fig 33: Removing Fuel Tank Cushion No. 1
    G00922876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 10 fuel tank cushions from the fuel tank.
  45. INSTALL FUEL TANK CUSHION No. 1 
    Fig 34: Installing Fuel Tank Cushion No. 1
    G00922877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 10 fuel tank cushions to the fuel tank.
  46. INSTALL FUEL TANK PROTECTOR No. 1 
    1. Using a riveter, install the fuel tank protector with the 4 new rivet.
      Fig 35: Installing Fuel Tank Protector With New Rivet Using Riveter
      G00922878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Install them with the rivet firmly pressed perpendicularly against the installation hole.
  47. INSTALL CHECK VALVE GASKET 
    1. Install a new gasket to the fuel tank inlet valve.
  48. INSTALL FUEL TANK INLET VALVE ASSY 
    1. Install the fuel tank inlet valve and check valve support with the 3 bolts.
      1. Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf) 
  49. INSTALL FUEL TUBE CLAMP No. 4 
    1. Install the fuel tube clamp with the bolt.
      1. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 
  50. INSTALL BREATHER TUBE SUB-ASSY 
    1. Push in the breather tube to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part.
    • After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
  51. INSTALL CHECK VALVE PROTECTOR 
    1. Install the check valve protector with 3 bolts.
      1. Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf) 
  52. INSTALL EVAPORATION VENT TUBE CLAMP No. 2 
    1. Install the evaporation vent tube clamp with the bolt.
      1. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 
  53. INSTALL FUEL EMISSION TUBE SUB-ASSY No. 1 
    1. Push in the fuel emission tube to the pipe until fuel tube connector makes "click" sound.
      NOTE:
      • Check if there is any damage or foreign objects on the connected part.
      • After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
  54. INSTALL FUEL TUBE CLAMP No. 4 
    1. Install the fuel tube clamp with the bolt.
      1. Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf) 
  55. INSTALL FUEL TANK ASSY 
    1. Set the mission jack to the fuel tank.
    2. Operate the mission jack and then connect the 2 fuel tank breather hoses.
    3. Install 2 fuel tank bands with the 4 bolts.
      1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
  56. CONNECT FUEL TANK MAIN TUBE SUB-ASSY 
    1. Push in the fuel tube connector to pipe until fuel tube connector, and install the fuel tube connector clip.
      NOTE:
      • Check if there is any damage or foreign objects on the connected part.
      • After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
  57. INSTALL CHARCOAL CANISTER ASSY 
    1. Install the charcoal canister with 3 bolts.
      1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 
    2. Connect pressure switching valve connector.
  58. CONNECT FUEL EVAPORATION TUBE SUB-ASSY No. 1 
    1. Push in the fuel evaporation tube to the pipe until fuel tube connector makes "click" sound.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part.
    • After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
  59. INSTALL PARKING BRAKE CABLE ASSY No. 2 
    1. Install the parking brake cable with 3 bolts.
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
  60. INSTALL PARKING BRAKE CABLE ASSY No. 3  
    1. Install the parking brake cable with 3 bolts.
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 
  61. INSTALL FRONT FLOOR HEAT INSULATOR No. 2 
    1. Install the front floor heat insulator with 2 nuts.
      1. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 
  62. INSTALL FRONT FLOOR HEAT INSULATOR No. 1 
    1. Install the front floor heat insulator with 3 nuts.
      1. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 
  63. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (See  OVERHAUL  ) 
  64. INSTALL EXHAUST PIPE ASSY CENTER 
    1. Using vernier calipers, measure the free length of the compression spring.
      1. Free length: 40mm (1.5748 in.) 
    2. Install a new gasket on the exhaust pipe front.
    3. Install a new gasket on the exhaust pipe center (rear side).
    4. Install the exhaust pipe center with the 2 compression springs, clamp and 3 bolts.
      1. Torque: 
        1. Front 43 N.m (440 kgf.cm, 32 ft.lbf) 
        2. Rear 32 N.m (330 kgf.cm, 24 ft.lbf) 
    5. Install the 2 exhaust pipe supports.
    6. Connect the oxygen sensor connector.
  65. INSTALL FRONT SEAT ASSY RH (See OVERHAUL  ) 
  66. INSTALL FUEL SUCTION TUBE SET GASKET (See  REMOVAL & INSTALLATION   ) 
  67. INSTALL FUEL PUMP ASSEMBLY (See  REMOVAL & INSTALLATION   ) 
  68. INSTALL FUEL TANK VENT TUBE SET PLATE (See  REMOVAL & INSTALLATION   ) 
  69. CONNECT FUEL TANK MAIN TUBE SUB-ASSY (See  REMOVAL & INSTALLATION   ) 
  70. INSTALL FUEL TANK PROTECTOR No. 2 (See  REMOVAL & INSTALLATION   ) 
  71. CHECK FUEL LEAK (See   FUEL SYSTEM   ) 
  72. CHECK EXHAUST GAS LEAK 
  73. INSTALL REAR FLOOR SERVICE HOLE COVER (See  REMOVAL & INSTALLATION   ) 
  74. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY (See  REMOVAL & INSTALLATION   ) 
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