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Fuel Tank: Removal

  1. PREVENT GASOLINE FROM SPILLING OUT 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. REMOVE REAR SEAT CUSHION ASSEMBLY (See  REMOVAL  ) 
  4. REMOVE REAR FLOOR SERVICE HOLE COVER (See step 4 under  REMOVAL  ) 
  5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY (See step 5 under  REMOVAL  ) 
  6. REMOVE FUEL TANK VENT TUBE SET PLATE (See step 6 under  REMOVAL  ) 
  7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (See step 7 under  REMOVAL  ) 
  8. DRAIN FUEL 
  9. REMOVE EXHAUST PIPE ASSEMBLY CENTER (See  REMOVAL  ) 
  10. DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO.2 
    1. Remove the set bolt and set nut of the parking brake cable assembly No.2.
      Fig 1: Removing Parking Brake Cable Assembly No.2
      G04377027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT PARKING BRAKE CABLE ASSEMBLY NO.3 
    1. Remove the set bolt and set nut of the parking brake cable assembly No.3.
      Fig 2: Removing Parking Brake Cable Assembly No.3
      G04377028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK PROTECTOR LOWER CENTER 
    1. Remove the 4 bolts and fuel tank protector.
      Fig 3: Removing Bolts And Fuel Tank Protector
      G04377029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel pump tube.
      1. Pinch the tab of the retainer to remove the lock claws and pull it down as shown in Fig 4.
      2. Pull out the fuel tank main tube.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
        • Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.
        • Do not use any tools in this operation.
        • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
        • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
          Fig 4: Removing Lock Claws
          G04377030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube No.1.
      1. Pinch the tube connector and then pull out the fuel tube No.1.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before this operation and clean the connector as necessary.
        • Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.
        • Do not use any tools in this operation.
        • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
        • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
          Fig 5: Pulling Out Fuel Tube No.1
          G04377031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set up a transmission jack underneath the fuel tank.
      Fig 6: Disconnecting Fuel Tank Vent Hose
      G04377032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 set bolts of the fuel tank bands.
    5. Remove the hose clamp and disconnect the fuel tank to filter pipe hose.
    6. Disconnect the fuel tank vent hose from the charcoal canister.
      1. Push the connector deep into the charcoal canister to release the locking pin.
      2. Pinch portion A.
      3. Pull out the connector.
    7. Remove the fuel tank.
    8. Remove the 2 pins and 2 fuel tank bands as shown in Fig 7.
      Fig 7: Removing Pins And Fuel Tank Bands
      G04377033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 4 clip nuts.
      Fig 8: Removing Clip And Nuts
      G04377034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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