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Fuel Tank: Removal

  1. REMOVE NO. 1 SEAT LEG COVER  (See REMOVAL )
  2. REMOVE NO. 2 SEAT LEG COVER  (See REMOVAL )
  3. REMOVE REAR SEAT CUSHION WITH COVER PAD SUB-ASSEMBLY LH  (See REMOVAL )
  4. REMOVE REAR FLOOR SERVICE HOLE COVER  (See REMOVAL  )
  5. DISCHARGE FUEL SYSTEM PRESSURE  (See FUEL SYSTEM  )
  6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY  (See REMOVAL  )
  7. DISCONNECT FUEL TANK VENT HOSE  (See REMOVAL  )
  8. REMOVE FUEL PUMP GAUGE RETAINER  (See REMOVAL  )
  9. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See REMOVAL  )
  10. DRAIN FUEL 
  11. REMOVE NO. 4 FRONT FLOOR HEAT INSULATOR 
    1. Remove the 2 nuts together with the insulator.
      Fig 1: Locating Insulator Nuts
      G04829109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 FUEL TANK PROTECTOR 
    1. Remove the bolt together with the clip and remove the No. 1 fuel tank protector.
      Fig 2: Locating No. 1 Fuel Tank Protector Bolts
      G04829110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Release the lock as shown in the illustration, then pull and remove the fuel tank main tube.
      NOTE:
      • Remove any dirt and foreign matter from the clip before performing this work.
      • Avoid any scratches or foreign matter on the parts when disconnecting them, as the quick connector has an O-ring that seals 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 parts by covering them with a plastic bag.
      • If the connector and pipe are stuck, disconnect the nylon tube by turning it by hand to release them.
        • Fig 3: Releasing Lock
        G05399497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DISCONNECT FUEL TANK VENT HOSE 
    1. Disconnect the fuel tank vent hose from the charcoal canister assembly.
      2. Fig 4: Disconnecting Fuel Tank Vent Hose Of Charcoal Canister Assembly
      G05399498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT FUEL TANK BREATHER HOSE 
    1. Release the lock as shown in the illustration, then pull and remove the fuel tank breather hose.
      NOTE:
      • Remove any dirt and foreign matter from the clip before performing this work.
      • Avoid any scratches or foreign matter on the parts when disconnecting, as the quick connector has an O-ring that seals 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 parts by covering them with a plastic bag.
      • If the connector and pipe are stuck, disconnect the nylon tube by turning it by hand to release them.
        • Fig 5: Disconnecting Fuel Tank Breather Hose
        G05399499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT LOWER FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Loosen the clamp and disconnect the fuel tank filler pipe.
      Fig 6: Locating Fuel Tank Filler Pipe Clamp
      G05399500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK ASSEMBLY 
    1. Remove the 4 bolts and remove the fuel tank.
      Fig 7: Locating Fuel Tank Bolts
      G05399501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel tank main tube from the fuel tank.
      Fig 8: Identifying Fuel Tank Main Tube
      G04829115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the fuel tank vent hose from the fuel tank.
      Fig 9: Identifying Fuel Tank Vent Hose
      G05399503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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