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Home >> Lexus >> 2011 >> LS 460L AWD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Fuel System (Service Information) >> Fuel Tank >> Removal >> Removal

Fuel Tank: Removal: Removal

  1. PRECAUTION  See step  1
  2. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure. Refer to PRECAUTION .
  3. REMOVE COWL TOP VENTILATOR LOUVER RH  . Refer to REMOVAL - Step 1
  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

  5. REMOVE REAR SEAT ASSEMBLY (for Power Seat) 
    1. Remove the rear seat assembly. Refer to REMOVAL .
  6. REMOVE REAR SEAT ASSEMBLY (for Ottoman) 
    1. Remove the rear seat assembly. Refer to REMOVAL .
  7. REMOVE REAR SEAT CUSHION ASSEMBLY (for Fixed Type) 
    1. Remove the rear seat cushion assembly. Refer to REMOVAL .
  8. REMOVE REAR FLOOR NO. 2 SERVICE HOLE COVER  See step  8
  9. REMOVE FUEL TANK MAIN AND RETURN TUBE 
    Fig 1: Locating Fuel Tank Main Tube And Fuel Tank Return Vent Tube
    GTY288316Courtesy 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.
  10. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the service hole cover and disconnect the fuel sender gauge connector.
      Fig 2: Locating Fuel Sender Gauge Connector
      GTY285119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    1. Remove the front exhaust pipe. Refer to REMOVAL .
  12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 
    1. Remove the propeller with center bearing shaft. Refer to REMOVAL .
  13. REMOVE FUEL TANK FILLER PIPE PROTECTOR 
    1. Remove the 2 nuts.
      Fig 3: Locating Tank Protector And Clip
      GTY125081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 2 clips and protector.
  14. REMOVE FUEL TANK PROTECTOR BRACKET SIDE 
    1. Remove the 2 bolts and protector bracket.
      Fig 4: Locating Protector Bracket Bolts
      GTY264321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel tank main tube.
      Fig 5: Disconnecting Fuel Main Tube
      GTY286374Courtesy 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.
      Fig 6: Disconnecting Fuel Main Tube
      GTY286374Courtesy 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.
      Fig 7: Locating Filler Pipe Hose Clamp
      GTY288175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Place a transmission jack under the fuel tank.
      Fig 8: Locating Fuel Tank Bands Bolts
      GTY274597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and 2 fuel tank bands.
    6. Lower the transmission jack 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 transmission jack slowly.

    7. Disconnect the fuel tank breather tube.
      Fig 9: Disconnecting Fuel Tank Breather Tube Sub-Assembly
      GTY288174Courtesy 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.
      Fig 10: Disconnecting Fuel Tank Vent Hose Sub-Assembly
      GTY262626Courtesy 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 transmission jack 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 transmission jack slowly.

  16. 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.
      Fig 11: Locating Set Plate Bolts
      GTY269253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel hose.
      Fig 12: Locating Fuel Hose
      GTY285164Courtesy 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.
  17. REMOVE FUEL SENDER GAUGE ASSEMBLY 
    1. Remove the 5 screws and fuel sender gauge.
      Fig 13: Locating Fuel Sender Gauge Screws
      GTY288173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket.
  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    Fig 14: Locating Fuel Tank Main Tube Clamps
    GTY276960Courtesy 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.
      Fig 15: Locating Fuel Hose Clamp
      GTY275437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 FUEL TANK PROTECTOR 
    Fig 16: Identifying Fuel Tank Protector Bolt And Clip
    GTY264053Courtesy 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.
  20. REMOVE FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose.
      Fig 17: Disconnecting Fuel Tank Vent Hose Sub-Assembly
      GTY288236Courtesy 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.
  21. REMOVE FUEL TANK CUSHION 
    1. Remove the 3 tank cushions.
      Fig 18: Identifying Tank Cushions
      GTY276231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the tank protector and 5 tank cushions.
      Fig 19: Identifying Tank Protector And Tank Cushions
      GTY275881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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