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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (See PRECAUTION  )

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE FRONT DOOR SCUFF PLATE LH 
    1. Disengage the 14 claws and remove the front door scuff plate.
      Fig 1: Identifying Front Door Scuff Plate Claws
      G05109691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE REAR DOOR SCUFF PLATE LH 
    1. Disengage the 6 claws and remove the rear door scuff plate.
      Fig 2: Identifying Rear Door Scuff Plate Claws
      G05109692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE REAR SEAT CUSHION ASSEMBLY LH 
    1. Remove the 2 bolts, then remove the rear seat cushion LH.
  6. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Pull back the floor carpet.
      Fig 3: Identifying Floor Carpet
      G05109693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the center floor silencer pad LH.
      Fig 4: Identifying Center Floor Silencer Pad LH
      G05109694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 screws from the center floor.
      Fig 5: Identifying Center Floor Screws
      G05109695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the connector.
      Fig 6: Identifying Connector
      G05109696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the clamp bolt, and disconnect the fuel tank to filler pipe hose.
      Fig 7: Identifying Clamp Bolt
      G05109697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Pinch the retainer to disengage the lock claws and pull out the No. 1 fuel tank breather tube.
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube.
      • To protect the tube, cover it with a vinyl bag after disconnecting it.
      • When the connector and the pipe are stuck, turn the retainer carefully to free and then disconnect the fuel tank tube.
      Fig 8: Disengaging Lock Claws
      G05109698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the 2 nuts and the fuel tank protector bracket, (for automatic transmission)
      Fig 9: Identifying Fuel Tank Protector Bracket Nuts (A/T)
      G05109699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and the fuel tank protector bracket, (for manual transmission)
      Fig 10: Identifying Fuel Tank Protector Bracket Nut (M/T)
      G05109700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 nuts and the fuel tank protector.
      Fig 11: Identifying Fuel Tank Protector Nuts
      G05109701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Pinch the retainer to disengage the lock claws and pull out the 2 fuel tank tubes.
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube.
      • To protect the tube, cover it with a vinyl bag after disconnecting it.
      • When the connector and the pipe are stuck, turn the retainer carefully to disconnect them.
        Fig 12: Identifying Lock Claws & Fuel Tank Tubes
        G05109702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT FUEL TANK VENT HOSE 
    1. Disconnect the fuel tank breather tube from the fuel tank.
      1. Push the connector deep inside.
      2. Pinch portion A.
      3. Pull out the connector.
      Fig 13: Pinching Portion A
      G05109703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK ASSEMBLY 
    1. Hold the fuel tank using a mission jack.
    2. Remove the 2 fuel tank bands.
      1. Remove the 2 bolts.
      2. Remove the 2 clips and 2 pins, then remove the 2 fuel tank bands.
        Fig 14: Identifying Fuel Tank Bands
        G05109704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 3 FUEL TANK PROTECTOR 
    1. Remove the 2 bolts and disengage the 3 claws, then remove the No. 3 fuel tank protector.
      Fig 15: Identifying Fuel Tank Protector Bolts
      G05109705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL TANK CUSHION 
    1. Remove the 4 fuel tank cushions from the fuel tank.
      Fig 16: Identifying Fuel Tank Cushions & Fuel Tank
      G05109706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK MAIN TUBE AND RETURN TUBE 
    1. Remove the 2 joint clips, and pull out the 2 fuel tank tubes.
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube by force.
      • After disconnecting, cover the fuel tube joint with a vinyl bag.
      • When the fuel tube joint and fuel suction plate are stuck, turn the fuel tank main tube carefully to free and then disconnect it. Likewise, disconnect the fuel tank return tube.
      Fig 17: Identifying Fuel Tank Main Tube And Return Tube
      G05109707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See REMOVAL  )
  17. DRAIN FUEL 
  18. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Pinch the retainer to disengage the lock claws and pull out the fuel tank breather tube.
      NOTE:
      • Check that there is no dirt or mud around the quick connector before performing this work, because the quick connector has an O-ring which seals the pipe and the connector. Clean the connector if necessary.
      • Do not use any tools in this work.
      • Do not bend or twist the nylon tube.
      • To protect the tube, cover it with a vinyl bag after disconnecting it.
      • When the connector and the pipe are stuck, turn the fuel tank breather tube carefully to disconnect them.
      Fig 18: Identifying Fuel Tank Breather Tube Sub-Assembly
      G05109708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the clamp bolt, and disconnect the fuel tank to filler pipe hose.
      Fig 19: Identifying Fuel Tank To Filler Pipe Hose With Clamp
      G05109709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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