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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE  (See REMOVAL  )
  2. REMOVE FUEL TANK CAP ASSEMBLY 
  3. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the 5 bolts and fuel tank protector.
    Fig 1: Locating Fuel Tank Protector Bolts
    G05628891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Detach the fuel tube clamp.
    2. Disconnect the fuel tank main tube.
    NOTE:
    • Check for foreign matter 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 forcefully bend or twist the nylon tube.
    • Check for foreign matter on the pipe seal surface. Clean if necessary.
    • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
    • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
    Fig 2: Disconnecting Fuel Tank Main Tube
    G05628892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DRAIN FUEL 
    1. Connect the cable to the negative (-) battery terminal.
    2. Connect the Techstream to the DLC3.
    3. Turn the engine switch on (IG).
      NOTE: Do not start the engine.
    4. Turn the Techstream main switch on.
    5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
    CAUTION:
    • Do not smoke or be near an open flame when working on the fuel system.
    • Secure good ventilation.
    • Keep gasoline away from rubber or leather parts.

    HINT:

    If the fuel pump does not operate, remove the fuel tube joint clip and No. 1 fuel tube joint, and drain fuel from the port shown in the illustration (Fig 3).

    Fig 3: Locating Fuel Tube Joint Port
    G05628893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
  7. REMOVE REAR NO. 1 SEAT ASSEMBLY LH 
    1. Remove the rear No. 1 seat assembly (See REMOVAL ).
  8. REMOVE REAR NO. 1 SEAT ASSEMBLY RH 
    1. Remove the rear No. 1 seat assembly (See REMOVAL ).
  9. REMOVE REAR NO. 1 SEAT PROTECTOR  (See REMOVAL )
  10. REMOVE REAR NO. 2 SEAT PROTECTOR  (See DISASSEMBLY )
  11. REMOVE REAR STEP COVER  (See REMOVAL )
  12. REMOVE REAR DOOR SCUFF PLATE LH  (See REMOVAL )
  13. REMOVE REAR DOOR SCUFF PLATE RH  (See REMOVAL )
  14. REMOVE REAR NO. 2 SEAT ASSEMBLY 
    1. Remove the rear No. 2 seat assembly (See REMOVAL ).
  15. REMOVE REAR FLOOR MAT REAR SUPPORT PLATE  (See REMOVAL )
  16. REMOVE LUGGAGE COMPARTMENT NO. 1 TRIM HOOK  (See REMOVAL )
  17. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH  (See REMOVAL )
  18. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH  (See REMOVAL )
  19. REMOVE AIR DUCT PLUG  (See REMOVAL )
  20. REMOVE REAR AIR DUCT GUIDE  (See REMOVAL )
  21. REMOVE FRONT FLOOR CARPET ASSEMBLY 
    1. Fold back the floor carpet.

      HINT:

      Fold back the carpet until it is possible to remove the air duct.

      Fig 4: Folding Back Floor Carpet
      G05628894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Remove the 2 screws and air duct.
      Fig 5: Locating Air Duct Screws
      G05628895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the service hole cover.
      Fig 6: Identifying Service Hole Cover
      G05628896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel pump and fuel sender gauge connector.
    Fig 7: Locating Fuel Sender Gauge Connector
    G05628897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT FUEL TANK RETURN TUBE 
    1. Detach the fuel tube clamp.
    2. Disconnect the fuel tank return tube.
    NOTE:
    • Check for foreign matter 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 forcefully bend or twist the nylon tube.
    • Check for foreign matter on the pipe seal surface. Clean if necessary.
    • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
    • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
    Fig 8: Disconnecting Fuel Tank Return Tube
    G05628898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT NO. 2 FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Detach the 2 fuel tube clamps.
    2. Disconnect the No. 2 fuel tank breather tube.
    NOTE:
    • Do not use any tools in this procedure.
    • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
    Fig 9: Locating No. 2 Fuel Tank Breather Tube
    G05628899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Detach the fuel tube clamp.
    2. Disconnect the fuel tank breather tube.
    NOTE:
    • Check for foreign matter 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 forcefully bend or twist the nylon tube.
    • Check for foreign matter on the pipe seal surface. Clean if necessary.
    • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
    • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
    Fig 10: Detaching Fuel Tube Clamp
    G05628900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Disconnect the fuel tank to filler pipe hose from the fuel tank filler pipe.
  27. REMOVE FUEL TANK SUB-ASSEMBLY 
    1. Place a transmission jack under the fuel tank.
      Fig 11: Locating Filler Pipe Hose
      G05628901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.
    3. Slowly lower the transmission jack slightly.
    Fig 12: Locating Bolts, Clips, Pins And Fuel Tank Bands
    G05628902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY 
    1. Remove the 3 fuel tube joint clips and pull out the 2 fuel tubes and No. 1 fuel tube joint.
      NOTE:
      • Remove any dirt and foreign matter on the fuel tube joint before performing this step.
      • 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 step 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 13: Removing Fuel Tube Joint Clips
      G05628903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel main tube and fuel return tube from the fuel tank.
    Fig 14: Locating Fuel Main Tube And Fuel Return Tube
    G05628904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Using SST, loosen the retainer.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      Fig 15: Fitting Tips Of SST Onto Ribs Of Retainer
      G05628905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Fit the tips of SST onto the ribs of the retainer.

      NOTE:
      • When the retainer is loosened, be careful as the pump and gauge tube will spring upward from the force of the spring.
      • Remove foreign matter around the fuel suction with pump and gauge before this operation.
    2. Remove the retainer.
    3. Remove the fuel suction with pump and gauge tube assembly from the fuel tank.
      NOTE: Be careful not to bend the arm of the fuel sender gauge.
    4. Remove the gasket from the fuel tank.
  30. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Remove the fuel tank to filler pipe hose from the fuel tank.
    Fig 16: Identifying Fuel Tank To Filler Pipe Hose From Fuel Tank
    G05628906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 1 FUEL TANK HEAT INSULATOR 
    1. Remove the fuel tube clamp from the No. 1 fuel tank heat insulator.
    2. Using needle-nose pliers, remove the 4 clips shown in the illustration (Fig 17) and then remove the No. 1 fuel tank heat insulator.
    Fig 17: Locating Fuel Tank Heat Insulator With Clips
    G05628907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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