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Removal [09/2015 - ]: Procedure

  1. PRECAUTION 
    WARNING:
    • Do not smoke or be near an open flame when working on the fuel system.
    • Keep gasoline away from rubber or leather parts.
    • Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Refer to PRECAUTION [09/2015 - ] ).

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    (Refer to PRECAUTION [09/2015 - ] )

  3. REMOVE COWL TOP VENTILATOR LOUVER RH 

    Refer to PROCEDURE - Step 1

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [09/2015 - ] ).

  5. REMOVE REAR NO. 1 AND NO. 2 SEAT ADJUSTER ASSEMBLY 
  6. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type) 

    (Refer to REMOVAL [09/2015 - ] )

  7. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER 

    See step  7

  8. REMOVE FUEL TANK MAIN AND RETURN TUBE 
    GTY653103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the fuel tank main tube and fuel tank return vent tube.
      1. Remove the 2 tube joint clips and disconnect the 2 fuel tubes.
        NOTE:
        • Remove any dirt and foreign matter on the fuel tube joint before performing this work.
        • 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 work 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.
  9. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the fuel sender gauge connector.
      GTY685838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    (Refer to REMOVAL [09/2015 - ] )

  11. REMOVE FUEL TANK FILLER PIPE PROTECTOR 
    1. Remove the 2 nuts.
      GTY674400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 2 clips and protector.
  12. REMOVE FUEL TANK PROTECTOR SIDE BRACKET 
    1. Remove the 2 bolts and protector side bracket.
      GTY665542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel tank main tube.
      GTY657863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matter contamination 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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 main tube.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
    2. Disconnect the fuel tank return vent tube.
      GTY682487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matter contamination 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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 return tube.
      • If the pipe and connector are stuck together, pinch the vent tube between your fingers and turn it carefully to free it. Then disconnect the fuel return tube.
    3. Loosen the clamp and disconnect the filler pipe hose.
      GTY630055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place a engine lifter under the fuel tank.
      GTY630051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and 2 fuel tank bands.
    6. Lower the engine lifter so that the fuel tank breather tube can be disconnected.
      NOTE:

      Make sure that no load is applied to the fuel filler pipe.

      HINT: 

      Lower the engine lifter slowly.

    7. Disconnect the fuel tank breather tube.
      GTY672457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matter contamination 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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 breather tube.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the breather tube.
    8. Disconnect the fuel tank vent hose.
      GTY638008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Pinch the retainer and then raise it.
        NOTE:
        • Check for any dirt and foreign matter contamination 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 allow any scratches or foreign matter on the parts when disconnecting them, as the vent hose contains the O-rings that seal the plug.
        • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
        • 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 vent hose.
        • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.
    9. Lower the engine lifter to remove the fuel tank from the vehicle.
      NOTE:
      • Do not allow the fuel tank to contact the vehicle, especially the differential.
      • Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.

      HINT: 

      Lower the engine lifter slowly.

  14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Remove the 8 bolts and, lower fuel tank protector and fuel vent tube set plate.
      GTY685907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel hose.
      GTY685712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel suction with pump and gauge tube from the fuel tank.
      NOTE:
      • Make sure that the sender gauge arm does not bend.
      • Do not damage the fuel suction tube with pump and gauge tube.
    4. Remove the gasket.
  15. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Remove the 5 screws and fuel sender gauge.
      GTY685999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket.
  16. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    GTY630061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 6 clamps and fuel tank main tube from the fuel tank.
    2. Remove the fuel hose clamp.
      GTY685937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 2 FUEL TANK PROTECTOR 
    GTY642609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and clip and No. 2 fuel tank protector from the fuel tank.
    2. Remove the clamp from the fuel tank.
  18. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose.
      GTY673313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matter contamination 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 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.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • 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 vent hose.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the vent hose.
  19. REMOVE FUEL TANK CUSHION 
    1. Remove the 3 tank cushions.
      GTY630054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the tank protector and 5 tank cushions.
      GTY630053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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