Removal & Installation And Disassembly & Reassembly

1. Remove the 3 bolts and the fuel tank filler hose cover.

Fig 1: Removing Bolts And Fuel Tank Filler Hose Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the fuel tank vent hose.
   Fig 2: Disconnecting Fuel Tank Vent Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Deeply push the connector to release the locking tab.
   2. Pinch portion A.
   3. Pull out the connector.
2. Disconnect the fuel tank main tube.
   Fig 3: Disconnecting Fuel Tank Main Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Pinch the tube connector and then pull out the fuel tank main tube.
   NOTE:

   • Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
   • Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
   • Do not use any tool 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 the connector are stuck, push and pull the connector to release and pull the connector out carefully.
   Fig 4: Identifying Tube Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the fuel tank to filler pipe hose.
   1. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
   Fig 5: Disconnecting Hose Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disconnect the fuel tube.
   1. Pinch the tube connector and then pull out the fuel tank main tube.
   NOTE:

   • Check if there is any dirt or mud around the connector before this operation and remove the dirt as necessary.
   • Be careful of mud because the quick connector has an O-ring which seals the pipe and connector that can be contaminated.
   Fig 6: Identifying O-Ring
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Do not use any tool 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 the connector are stuck, push and pull the connector to release and pull the connector out carefully.
   Fig 7: Disconnecting Connector
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 2 wire harness clamps.
   Fig 8: Removing Wire Harness Clamps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Set up a transmission jack under the fuel tank.
7. Remove the 6 set bolts of the 3 fuel tank bands.
   Fig 9: Removing Set Bolts Of Fuel Tank Bands

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. While operating the transmission jack, unfasten the 4 claws for the wire harness and disconnect the fuel pump connector and vapor pressure sensor connector, then remove the fuel tank and the 3 fuel tank bands from the vehicle

Fig 10: Identifying Vapor Pressure Sensor

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Loosen the hose clamp bolt and remove the fuel tank to filler pipe hose from the fuel tank.

Fig 11: Loosening Hose Clamp Bolt

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1. Remove the hose of the fuel tank vent hose from the 3 hose clamps.
2. Remove the fuel tank vent hose.
   Fig 12: Removing Fuel Tank Vent Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Deeply push the connector to release the locking tab.
   2. Pinch portion A.
   3. Pull out the connector.

1. Install a new fuel tank to filler pipe hose as shown in the illustration.

Fig 13: Installing New Fuel Tank To Filler Pipe Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  . 

1. Set up the fuel tank to the transmission jack.
2. While operating the transmission jack, fasten the 4 claws for the wire harness and connect the fuel pump connector and vapor pressure sensor connector, then install the fuel tank and the 3 fuel tank bands to the vehicle.
3. Tighten the 6 set bolts of the 3 fuel tank bands.

   Torque: 33 N.m (336 kgf.cm, 24 ft.lbf) 

4. Install the 2 wire harness clamps.
5. Connect the fuel tube.
   1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.
   Fig 14: Installing Wire Harness Clamps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check if there is any damage or foreign objects on the connected part.
   • After connecting, check if the connector and the pipe are securely connected by pulling on them.
6. Connect the fuel tank to filler pipe hose as shown in the illustration.
   Fig 15: Connecting Fuel Tank To Filler Pipe Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the fuel tank main tube.
   1. Push in the fuel tube connector to the pipe until fuel tube connector makes "click" sound.
   Fig 16: Connecting Fuel Tank Main Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check if there is any damage or foreign objects on the connected part.
   • After connecting, check if the connector and the pipe are securely connected by pulling on them.
8. Connect the fuel tank vent hose.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)