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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (See FUEL SYSTEM ).
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE FUEL SUCTION TUBE ASSEMBLY 
    1. Remove the fuel suction tube assembly from the fuel tank assembly (See REMOVAL ).
  4. DRAIN FUEL 
  5. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  6. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the 4 bolts and the fuel tank protector sub-assembly.
    Fig 1: Locating Fuel Tank Protector Sub-Assembly Bolts
    G06009797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SEPARATE PARKING BRAKE CABLE 
    1. Remove the 4 bolts, and separate the parking brake cables.
    Fig 2: Locating Parking Brake Cables Bolts
    G06009796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT FUEL TANK VENT HOSE 
    1. Disconnect the fuel tank vent hose.
    2. Pull the fuel tank vent hose out of the pipe.
      NOTE:
      • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if 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.
      • Only disconnect the quick connector by hand.
      • Do not bend, kink or twist the nylon tubes.
      • Protect the connector by covering it with a plastic bag.
    Fig 3: Disconnecting Fuel Tank Vent Hose
    G06041811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT BREATHER TUBE FUEL HOSE 
    1. Disconnect the breather tube fuel hose.
      1. Remove the checker of the fuel tube connector from the pipe.
      2. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if 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.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes.
        • Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
        Fig 4: Disconnecting Breather Tube Fuel Hose
        G06041941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the fuel breather tube fuel hose.
      Fig 5: Locating Fuel Breather Tube Fuel Hose
      G06009800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube.
      1. Pinch the tabs of the retainer of the fuel tube connector to disengage the lock claws and push it down as shown in the illustration.
      2. Pull the fuel tank main tube out of the pipe.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if 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.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes.
        • Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
        Fig 6: Disconnecting Fuel Tank Main Tube
        G06041943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.
      Fig 7: Identifying Fuel Tank Filler Pipe Cover Claw
      G06009938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the hose clamp bolt, then disconnect the fuel tank filler pipe hose from the fuel tank.
      Fig 8: Locating Hose Clamp Bolt
      G05193297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK ASSEMBLY 
    1. Hold the fuel tank using a transmission jack.
      Fig 9: Holding Fuel Tank Using A Transmission Jack
      G06009804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts, then remove the 2 No. 1 fuel tank bands.
    3. Operate the transmission jack, then remove the fuel tank.
      Fig 10: Locating No. 1 Fuel Tank Bands Bolts
      G06009805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the fuel tank main tube from the fuel tank.
      Fig 11: Locating Fuel Tank Main Tube
      G05193299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL TANK VENT HOSE 
    1. Remove the fuel tank vent hose from the fuel tank clamp.
      Fig 12: Locating Fuel Tank Clamp
      G05193300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK CUSHION 
    1. Remove the fuel tank cushions from the fuel tank.
      Fig 13: Identifying Fuel Tank Cushions
      G06009808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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