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Home >> Toyota >> 2007 >> Prius Base >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System (1NZ-FXE) >> Fuel Tank >> Removal

Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  2. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See  REMOVAL  ) 
  3. REMOVE FRONT FLOOR PANEL BRACE (See  REMOVAL  ) 
  4. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See  REMOVAL  ) 
  5. REMOVE REAR SEAT CUSHION ASSEMBLY (See  REMOVAL  ) 
  6. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Remove the butyl tape and rear floor service hole cover.
    2. Disconnect the fuel pump connector.
    3. Disconnect the wire to wire connector.
      Fig 1: Removing Rear Floor Service Hole Cover
      G04472865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel tank to canister tube.
      1. Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tank to canister tube from the pipe.
        NOTE:
        • Remove dirt or foreign objects on the fuel tube connector before this procedure.
        • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-ring that seals the pipe.
        • Perform this work by hand. Do not use any tools.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank to canister tube.
        • If the fuel tube connector and pipe are stuck, push and pull them to release them.
          Fig 2: Disconnecting Fuel Tank To Canister Tube
          G04472866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the No. 2 fuel tank main tube.
      1. Remove the checker of the fuel tube connector from the pipe.
      2. Pinch the retainer of the fuel tube connector, and then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe.
        NOTE:
        • Remove dirt or foreign objects on the fuel tube connector before this procedure.
        • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-ring that seals the pipe.
        • Perform this work by hand. Do not use any tools.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the connecting part by covering it with a plastic bag after disconnecting the No. 2 fuel tank main tube.
        • If the fuel tube connector and pipe are stuck, push and pull them to release them.
          Fig 3: Disconnecting No. 2 Fuel Tank Main Tube
          G04472867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel tank vent hose.
      1. Pinch the retainer and pull out the fuel tank vent hose connector with the fuel tank vent hose connector pushed to the pipe side to disconnect the fuel tank vent hose from the canister filter.
        NOTE:
        • Remove dirt or foreign objects on the fuel tank vent hose connector before this procedure.
        • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank vent hose connector has the O-ring that seals the pipe.
        • Perform this work by hand. Do not use any tools.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
        • If the fuel tank vent hose connector and pipe are stuck, push and pull them to release them.
          Fig 4: Disconnecting Fuel Tank Vent Hose
          G04472868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the fuel suction tube.
      1. Pinch the retainer and pull out the suction tube connector with the suction tube connector pushed to the pipe side to disconnect the fuel suction tube from the fuel tank to filler pipe.
        NOTE:
        • Remove dirt or foreign objects on the quick connector before this procedure.
        • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel suction tube connector has the O-ring that seals the pipe.
        • Perform this work by hand. Do not use any tools.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel suction tube.
        • If the fuel suction tube connector and pipe are stuck, push and pull them to release them.
          Fig 5: Disconnecting Fuel Suction Tube
          G04472869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the No. 1 canister tube.
      1. Pinch the retainer and pull out the No. 1 canister tube connector with the No. 1 canister tube connector pushed to the pipe side to disconnect the No. 1 canister tube from the fuel tank to filler pipe.
        NOTE:
        • Remove dirt or foreign objects on the quick connector before this procedure.
        • Do not allow any scratches or foreign objects on the parts when disconnecting them as the No. 1 canister tube connector has the O-ring that seals the pipe.
        • Perform this work by hand. Do not use any tools.
        • Do not forcibly bend, twist or turn the nylon tube.
        • Protect the connecting part by covering it with a plastic bag after disconnecting the tank to canister tube.
        • If the No. 1 canister tube connector and pipe are stuck, push and pull them to release them.
          Fig 6: Disconnecting No. 1 Canister Tube
          G04472870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Set a transmission jack to the fuel tank.
    7. Remove the fuel filler pipe clamp and fuel tube connector from the fuel tank inlet pipe.
      Fig 7: Removing Fuel Filler Pipe Clamp And Fuel Tube Connector
      G04472871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 4 bolts and No. 1 fuel tank band RH and LH.
    9. Operate the transmission jack, and then disconnect the fuel tank inlet pipe.
    10. Operate the transmission jack, and then remove the fuel tank.
  8. REMOVE NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the 3 nuts and rear fuel tank bracket.
    2. Disconnect the wire to wire connector from the rear fuel tank bracket.
      Fig 8: Removing Nuts From Rear Fuel Tank Bracket
      G04472872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 2 fuel tank main tube from the clamp.
    4. Remove the checker of the main tube connector from the pipe.
    5. Pinch the retainer of the main tube connector, then pull out the fuel tube connector to disconnect the No. 2 fuel tank main tube from the pipe.
      NOTE:
      • Remove dirt or foreign objects on the fuel tube connector before this procedure.
      • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tube connector has the O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the connecting part by covering it with a plastic bag after disconnecting the No. 2 fuel tank main tube.
      • If the fuel tube connector and pipe are stuck, push and pull them to release them.
        Fig 9: Removing No. 2 Fuel Tank Main Tube Sub-Assembly
        G04472873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel suction tube from the 2 No. 1 fuel tube clamps.
    2. Pinch the retainer and pull out the suction tube connector with the quick connector pushed to the pipe side to disconnect the fuel suction tube from the pipe.
      NOTE:
      • Remove dirt or foreign objects on the quick connector before this procedure.
      • Do not allow any scratches or foreign objects on the parts when disconnecting them as the suction tube connector has the O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel suction tube.
      • If the quick connector and pipe are stuck, push and pull them to release them.
        Fig 10: Removing Fuel Suction Tube Sub-Assembly
        G04472874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL TANK TO CANISTER TUBE 
    1. Disconnect the fuel tank to canister tube from the clamp.
    2. Disconnect the fuel tank to canister tube from the 2 No. 1 fuel tube clamps.
    3. Remove the fuel tank to canister tube from the fuel tank.
      Fig 11: Removing Fuel Tank To Canister Tube
      G04472875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRAP CANISTER WITH PUMP MODULE 
    1. Disconnect the VSV connector.
    2. Remove the clamp from the fuel tank vent hose and canister hose.
    3. Remove the fuel tank vent hose from the 2 fuel tube clamps.
    4. Remove the 2 bolts and trap canister with pump module and disconnect the ground terminal of the fuel tank wire.
      Fig 12: Removing Trap Canister With Pump Module
      G04472876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the gasket from the fuel tank.
      Fig 13: Removing Gasket From Fuel Tank
      G04472877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 clamps from the trap canister with pump module.
      Fig 14: Removing Clamps From Trap Canister With Pump Module
      G04472878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK VENT HOSE 
    1. Pinch the retainer and pull out the fuel tank vent hose connector with the fuel tank vent hose connector pushed to the fuel tank vent hose side to disconnect the fuel tank vent hose from the trap with outlet valve canister.
      NOTE:
      • Remove dirt of foreign objects on the fuel tank vent hose connector before this procedure.
      • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank vent hose connector has the O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
      • If the fuel tank vent hose connector and pipe are stuck, push and pull them to release them.
        Fig 15: Removing Fuel Tank Vent Hose
        G04472879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK WIRE 
    1. Remove the clamp as shown in Fig 16 (A).
    2. Disconnect the VSV connector as shown in Fig 16 (B).
    3. Disconnect the vapor pressure sensor connector as shown in Fig 16 (C).
    4. Remove the 3 wire harness clamps as shown in Fig 16 (D).
      Fig 16: Removing Fuel Tank Wire
      G04472880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CANISTER 
    1. Disconnect the canister hose from the fuel tank retainer.
    2. Disconnect the No. 1 canister outlet hose from the fuel tank.
    3. Remove the bolt, 2 nuts and canister.
      Fig 17: Removing Canister Bolts
      G04472881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut from the fuel tank.
      Fig 18: Removing Nut From Fuel Tank
      G04472882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK PRESSURE SENSOR 
    1. Remove the tube joint clip, then pull out the fuel tank pressure sensor from the fuel tank retainer LH.
      NOTE:
      • Remove dirt or foreign objects on fuel tank pressure sensor before this procedure.
      • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank pressure sensor has the O-ring that seals the plug.
      • Perform this work by hand. Do not use any tools.
        Fig 19: Removing Fuel Tank Pressure Sensor
        G04472883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL TANK RETAINER LH 
    1. Insert a clip remover between the fuel tank retainer and gasket, then remove the fuel tank retainer by lifting it little by little.
      NOTE:
      • The fuel tank retainer is made of resin and easily damaged if removed or installed forcibly. Handle the part correctly to ensure proper sealing.
      • After removing the fuel tank retainer, check that the contact surface of the fuel tank retainer on the fuel tank is not damaged.
        Fig 20: Removing Fuel Tank Retainer
        G04472884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the fuel tank.
      Fig 21: Removing Gasket From Fuel Tank
      G04472885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 1 FUEL TUBE CLAMP 
    1. Remove the 2 clamps from the fuel tank.
      Fig 22: Removing 2 Clamps From Fuel Tank
      G04472886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE NO. 1 FUEL TANK CUSHION 
    1. Remove the 9 cushions from the fuel tank.
      Fig 23: Removing 9 Cushions From Fuel Tank
      G04472887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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