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Home >> Toyota >> 2007 >> Tacoma PreRunner, 2D Pickup >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System (2TR-FE) >> Fuel Tank >> Removal

Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM  ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. DISCONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Remove the fuel pipe clamp.
      Fig 1: Identifying Fuel Pipe Clamp
      G04409244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank main tube and fuel tank return tube.
      1. Pinch the retainer as shown in Fig 2, then pull the fuel tube connectors out of the pipes.
        Fig 2: Pinching Retainer Then Pull Out Fuel Tube Connectors
        G04409245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Remove any dirt and foreign objects from the fuel tube connector before performing this work.
        • Do not allow any scratches or foreign objects on the parts when disconnecting, 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 disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
        • If the fuel tube connector and pipe are stuck, push and pull to release them.
  4. REMOVE FUEL TANK ASSEMBLY 
    1. Loosen the clamp bolt.
    2. Disconnect the fuel breather tube.
      1. Remove the checker of the fuel tube connector from the pipe.
      2. Pinch the retainer of the fuel tube connector, then pull the tube connector out of the pipe.
        NOTE:
        • Remove any dirt and foreign objects from the fuel tube connector before performing this work.
        • Do not allow any scratches or foreign objects on the parts when disconnecting, 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 disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
        • If the fuel tube connector and pipe are stuck, push and pull to release them.
          Fig 3: Identifying Fuel Tank Assembly
          G04409246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Hold the fuel tank using the mission jack.
    4. Remove the 2 fuel tank bands.
      1. Remove the 2 bolts.
      2. Remove the 2 clips and 2 pins, then remove the 2 fuel tank bands.
      Fig 4: Identifying Clips And Pins
      G04409247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the fuel pump cover.
    6. Slightly jack the fuel tank down and separate the fuel tank to filler pipe hose from the inlet pipe.
      NOTE: Slowly jack down the fuel tank so as not to tear the wire harness and hose.
    7. Disconnect the fuel pump connector.
    8. Disconnect the fuel tank vent hose.
      1. Pinch the retainer and pull the fuel tank vent hose connector out of the charcoal canister to disconnect the fuel tank vent hose from the charcoal canister.
        NOTE:
        • Remove any dirt and foreign objects from the fuel tank vent hose connector before performing this work.
        • Do not allow any scratches of foreign objects on the parts when disconnecting, 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 disconnected part by covering it with a vinyl bag after disconnecting the fuel tank vent hose.
        • If the fuel tank vent connector and pipe are stuck, push and pull to release them.
        Fig 5: Pinching Retainer And Pulling Fuel Tank Vent Hose Connector
        G04409248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the fuel tank assembly.
  5. REMOVE FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Remove the 2 joint clips, then remove the fuel tank main tube and fuel tank return tube.
      NOTE:
      • Remove any dirt and foreign objects from the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects on the parts when disconnecting, 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 disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull to release them.
        Fig 6: Identifying Fuel Tank Main Tube And Fuel Tank Return Tube
        G04409249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL SUCTION WITH PUMP & GAUGE TUBE ASSEMBLY 
    NOTE: Protect the connector and tube joint with masking tape or equivalent to prevent any foreign objects from sticking to them. Clean any dirt and foreign objects from the fuel suction tube assembly before removing.
    1. Using a SST, loosen the retainer.

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

      Fig 7: Loosening Retainer Using SST
      G04409250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The ribs on the retainer can be fitted into a tip of the SST.

    2. Remove the retainer.
    3. Pull the fuel pump assembly out of the fuel tank.
      NOTE: Be careful not to bend the arm of the sender gauge.
    4. Remove the gasket from the fuel tank.
    Fig 8: Identifying Fuel Tank
    G04409251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DRAIN FUEL 
  8. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the clamp bolt, then remove the fuel tank to filler pipe hose.
    Fig 9: Identifying No. 1 Fuel Tank To Filler Pipe Hose
    G04409252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 FUEL TANK PROTECTOR 
    1. Remove the 4 clips, then remove the fuel tank protector.
      Fig 10: Identifying Fuel No. 1 Fuel Tank Protector Clips
      G04409253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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