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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 REMOVAL )
  5. SEPARATE FUEL PUMP TUBE SUB-ASSEMBLY  (See REMOVAL )
  6. REMOVE FUEL TANK VENT TUBE SET PLATE  (See REMOVAL )
  7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE  (See 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: Disconnect Parking Brake Cable Assembly No .2
    G04997079Courtesy 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: Disconnect Parking Brake Cable Assembly No.3
    G04997080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK PROTECTOR LOWER CENTER 
    1. Remove the 4 bolts and fuel tank protector.
    Fig 3: Remove Fuel Tank Protector Lower Center
    G04997081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel pump tube.
      1. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.
      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.
        • It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Do not use any tools in this operation.
        • Do not bend, kink 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 Fuel Tank Assembly
      G04997082Courtesy 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.
        • It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Do not use any tools in this operation.
        • Do not bend, kink 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: Disconnecting Fuel Tube No. 1
      G04974959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set up a transmission jack underneath the fuel tank.
    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.
      Fig 6: Disconnecting Fuel Tank Vent Hose From Charcoal Canister
      G04997084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the fuel tank.
    8. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
      Fig 7: Removing Pins And Fuel Tank Bands
      G04974962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 4 clip nuts.
    Fig 8: Locating Clip And Nuts
    G04997086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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