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Fuel Tank: Removal

  1. REMOVE REAR SEAT CUSHION WITH COVER PAD SUB-ASSEMBLY  (See REMOVAL  )
  2. DISCHARGE FUEL SYSTEM PRESSURE  (See REMOVAL  )
  3. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY  (See REMOVAL  )
  4. REMOVE FUEL PUMP GAUGE RETAINER  (See REMOVAL  )
  5. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See REMOVAL  )
  6. DRAIN FUEL 
  7. REMOVE CHARCOAL CANISTER ASSEMBLY 

    Refer to the procedures under "REMOVE CHARCOAL CANISTER ASSEMBLY" (See REMOVAL ).

  8. REMOVE NO. 2 CENTER EXHAUST PIPE ASSEMBLY 
    1. Remove the 4 bolts and 2 compression spring and remove the No. 2 center exhaust pipe assembly.
      Fig 1: Locating Center Exhaust Pipe Assembly Bolts
      G05387557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE REAR FLOOR SIDE MEMBER COVER RH 
    1. Remove the nut, grommet and 2 bolts, then remove the rear floor side member cover RH.
      Fig 2: Locating Rear Floor Side Member Cover RH
      G05387558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE REAR FLOOR SIDE MEMBER COVER LH 
    1. Remove the nut, grommet and 2 bolts, then remove the rear floor side member cover LH.
      Fig 3: Identifying Rear Floor Side Member Cover LH
      G05387559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY 
    1. Remove the 4 bolts and remove the rear floor side member brace sub-assembly.
      Fig 4: Locating Rear Floor Side Member Brace Sub-Assembly Bolts
      G05387560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the 3 bolts and a nut, then remove the No. 1 fuel tank protector sub-assembly.
      Fig 5: Locating Fuel Tank Protector Sub-Assembly And Bolts
      G05387561Courtesy 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.
      Fig 6: Identifying Fuel Tank Main Tube
      G05387562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove any dirt and foreign matter from the clip before performing this work.
      • Avoid getting 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 it.
  14. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Disconnect the fuel tank to filler pipe hose.
      Fig 7: Locating Fuel Tank To Filler Pipe Hose
      G05387563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 6 FUEL TANK BREATHER TUBE (a) Release the lock as shown in the illustration, then pull and remove the No. 6 fuel tank breather tube. 
    NOTE:
    • Remove any dirt and foreign matter from the clip before performing this work.
    • Avoid getting 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 it.
      Fig 8: Identifying Fuel Tank Breather Tube
      G05387564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL TANK ASSEMBLY 
    1. Remove the 2 bolts and separate the parking brake cable assembly.
      Fig 9: Identifying Parking Brake Cable Assembly Bolts
      G05387565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set the mission jack under the fuel tank.
    3. Remove the 4 bolts and remove the fuel tank assembly.
      Fig 10: Identifying Fuel Tank Assembly Bolts
      G05387566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK CUSHION 
    1. Remove the No. 1 fuel tank cushion and 3 No. 2 fuel tank cushions.
      Fig 11: Identifying Fuel Tank Cushion
      G05387567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the fuel tank main tube sub-assembly from the fuel tank.
      Fig 12: Identifying & Removing Fuel Tank Main Tube Sub-Assembly
      G05387568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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