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Fuel Tank ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Camry. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION  ) 
  2. REMOVE REAR SEAT CUSHION ASSEMBLY (See  OVERHAUL  ) 
  3. REMOVE REAR FLOOR SERVICE HOLE COVER (See  REPLACEMENT   ) 
  4. SEPARATE FUEL PUMP TUBE SUB-ASSY (See  REPLACEMENT   ) 
  5. REMOVE FUEL TANK VENT TUBE SET PLATE (See  REPLACEMENT   ) 
  6. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See  REPLACEMENT   ) 
  7. DRAIN FUEL 
  8. REMOVE FLOOR PANEL BRACE REAR (See  REPLACEMENT  ) 

    For floor panel brace (see COMPONENTS )

  9. REMOVE EXHAUST PIPE ASSY CENTER 
    1. Remove the 2 bolts, 4 nuts, exhaust pipe and 2 gaskets.
  10. DISCONNECT PARKING BRAKE CABLE ASSY NO. 2 
    1. Remove the set bolt and the set nut of the parking brake cable.
      Fig 1: Disconnect Parking Brake Cable Assy NO. 2
      G02624513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT PARKING BRAKE CABLE ASSY NO. 3 
    1. Remove the set bolt and the set nut of the parking brake cable.
      Fig 2: Disconnecting Parking Brake Cable Assy NO. 3
      G02624514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK PROTECTOR LOWER CENTER 
    1. Remove the 4 bolts and fuel tank protector.
      Fig 3: Removing Fuel Tank Protector (Lower Center)
      G02624515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK ASSY 
    1. Disconnect the fuel pump tube.
      1. Pinch the tab of the retainer to remove the lock claws and pull down it as shown.
      2. Pull out the fuel tank main tube.
        Fig 4: Disconnecting Fuel Pump Tube
        G02624516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before this operation, check the connector for dirt, mud or other contamination.
      • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
      • Do not use any tools in this operation.
      • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
        Fig 5: Identifying Fuel Tube Connector And Retainer
        G02624517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube No. 1.
      1. Pinch the tube connector and then pull out the fuel tube No. 1.
        Fig 6: Pinching Tube Connector
        G02624518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before this operation, check the connector for dirt, mud or other contamination.
      • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
      • Do not use any tools in this operation.
      • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
        Fig 7: Identifying Nylon Tube And Tube Connector
        G02624519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set up a transmission jack underneath the fuel tank.
    4. Remove the 2 set bolts of the fuel tank bands.
    5. Remove the hose clamp and disconnect the fuel tank to filler pipe hose.
    6. Disconnect the fuel tank vent hose from the charcoal canister.
      1. Push the connector deep into the charcoal canister to release the locking pin.
      2. Pinch portion A.
      3. Pull out the connector.
    7. Remove the fuel tank.
      Fig 8: Disconnecting Fuel Tank To Filler Pipe Hose
      G02624520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 2 pins and 2 fuel tank bands as shown.
      Fig 9: Removing Pins And Fuel Tank Bands
      G02624521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 4 clip nuts.
      Fig 10: Removing Clip Nuts
      G02624522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL TANK VENT HOSE 
    1. Push the connector deep into the charcoal canister to release the locking pin.
    2. Pinch portion A.
    3. Pull out the connector.
      Fig 11: Removing Fuel Tank Vent Hose
      G02624523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL PUMP TUBE SUB-ASSY 
    1. Remove the fuel pump tube from the fuel main tube support.
      Fig 12: Removing Fuel Pump Tube Sub-Assy
      G02624524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL MAIN TUBE SUPPORT 
    1. Remove the bolt and tube support.
      Fig 13: Removing Fuel Main Tube Support
      G02624525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK CUSHION NO. 2 
  18. INSTALL FUEL TANK CUSHION NO. 2 
    1. Install 7 new fuel tank cushions to the fuel tank.
    Fig 14: Installing Fuel Tank Cushions To Fuel Tank
    G02624526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL MAIN TUBE SUPPORT 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  20. INSTALL FUEL PUMP TUBE SUB-ASSY 
  21. INSTALL FUEL TANK VENT HOSE 
  22. INSTALL FUEL TANK ASSY 
    1. Install the 4 clip nuts.
    2. Install the 2 fuel tank bands with the 2 pins.
    3. Connect the fuel tank vent hose.
    4. Connect the fuel tank inlet pipe with the fuel filler pipe clamp.
    5. Tighten the set 2 bolts of the fuel tank bands.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

    6. Connect the fuel tube No. 1.
      1. Push the fuel tube connector into the pipe until fuel tube connector makes "click" sound.
      NOTE:
      • Check if there is any damage or foreign objects on the connected part.
      • After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart.
        Fig 15: Connecting The Fuel Tube
        G02624527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the fuel pump tube.
      1. Push in the fuel tube connector to the pipe until, and push up retainer to the claws lock.
      NOTE:
      • Check if there is any damage or foreign objects on the connected part.
      • After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart.
        Fig 16: Connecting Fuel Pump Tube
        G02624528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FUEL TANK PROTECTOR LOWER CENTER 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  24. INSTALL PARKING BRAKE CABLE ASSY NO. 3 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  25. INSTALL PARKING BRAKE CABLE ASSY NO. 2 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  26. INSTALL EXHAUST PIPE ASSY CENTER 
    1. Install 2 new gaskets and the exhaust pipe with the 2 bolts and 4 new nuts.

      Torque: 56 N.m (571 kgf.cm, 41 ft.lbf) 

  27. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See  REPLACEMENT   ) 
  28. INSTALL FUEL TANK VENT TUBE SET PLATE (See  REPLACEMENT   ) 
  29. CONNECT FUEL PUMP TUBE SUB-ASSY (See  REPLACEMENT   ) 
  30. ADD FUEL 
  31. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  32. CHECK FOR EXHAUST GAS LEAKS 
  33. INSTALL REAR FLOOR SERVICE HOLE COVER (See  REPLACEMENT  ) 
  34. INSTALL REAR SEAT CUSHION ASSEMBLY (See  OVERHAUL  ) 
  35. INSTALL FLOOR PANEL BRACE REAR (See  REPLACEMENT  ) 

    For floor panel brace (see COMPONENTS )

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