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Home >> Toyota >> 2007 >> Tundra Base, 4.0 U >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System (1GR-FE) >> Fuel Tank >> Removal

Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE  (see REMOVAL  )
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:
    • Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
    • After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and settings. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
  3. REMOVE FUEL TANK CAP 
  4. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Detach the lock claw by lifting up the cover, as shown in the illustration.
      2. Fig 1: Detaching Lock Claw By Lifting Up Cover
      G05151949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch and pull the main tube connector to disconnect the connector from the pipe.
      NOTE:
      • Check for foreign matter 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 forcefully bend or twist the nylon tube.
      • Check for foreign matter on the pipe seal surface. Clean if necessary.
      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
      • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
  5. DISCONNECT FUEL TANK RETURN TUBE 
    1. Detach the lock claw by lifting up the cover, as shown in the illustration.
      2. Fig 2: Detaching Lock Claw By Lifting Up Cover
      G05151950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch and pull the return tube connector to disconnect the connector from the pipe.
      NOTE:
      • Check for foreign matter 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 forcefully bend or twist the nylon tube.
      • Check for foreign matter on the pipe seal surface. Clean if necessary.
      • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
      • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
  6. DISCONNECT VENT LINE HOSE 
    1. Pull up the retainer and disconnect the vent line hose.
      Fig 3: Pulling Up Retainer
      G05151951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not use any tools in this procedure.
      • Check for any dirt and foreign matter contamination in the valve and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the valve and connector.
  7. DISCONNECT WIRE HARNESS 
    1. Detach the harness clamp from the fuel tank.
      Fig 4: Identifying Harness Clamp From Fuel Tank
      G05151952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Detach the lock claw by lifting up the cover, as shown in the illustration.
      2. Fig 5: Identifying Fuel Tank Assembly
      G05151953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank breather tube from the inlet pipe.
    3. Disconnect the fuel tank to filler pipe hose from the inlet pipe.
    4. Detach the filler pipe hose and breather tube from the No. 1 breather tube clamp.
  9. DISCONNECT NO. 1 CANISTER OUTLET HOSE 
    1. Disconnect the canister outlet hose from the inlet pipe.
    2. Detach the hose from the No. 1 breather tube clamp.
  10. REMOVE FUEL TANK ASSEMBLY 
    1. Set a mission jack underneath the fuel tank.
    2. Remove the 2 bolts, 2 clips, 2 pins and 2 fuel tank bands.
      3. Fig 6: Identifying Fuel Tank Bolts And Clips With Pins
      G05151954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Slowly lower the mission jack slightly.
      NOTE: Be careful not to cut the wirings.
    4. Detach the wire harness clamp from the fuel tank as shown in the illustration.
    5. Disconnect the fuel pump connector and lower the mission jack.
      Fig 7: Identifying Fuel Pump Connector
      G05151955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before this procedure, check the connector for dirt, mud or other contamination.
      • Do not use any tools in this procedure.
  11. REMOVE FUEL TANK INLET PIPE SUB-ASSEMBLY 
    1. Remove the 2 nuts and inlet pipe.
      Fig 8: Identifying Inlet Pipe Nuts
      G05151956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 1 FUEL TANK HEAT INSULATOR 
    1. Remove the nut from the heat insulator.
    2. Using needle-nose pliers, remove the 4 clips shown in the illustration and then remove the heat insulator.
      Fig 9: Identifying Clips And Nuts
      G05151957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Remove the filler pipe hose from the fuel tank.
      Fig 10: Identifying Filler Pipe Hose From Fuel Tank
      G05151958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Remove the 2 tube joint clips and pull out the 2 fuel tank tubes.
      Fig 11: Identifying Tube Joint Clips
      G05151959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. Using SST, loosen the retainer.
      Fig 12: Loosening Retainer Using SST
      G05151960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT:

      Fit the tips of SST onto the ribs of the retainer.

      NOTE:
      • When the retainer is loosened, be careful as the pump and gauge tube will spring upward from the force of the spring.
      • Clean the pump and gauge tube before this operation.
    3. Remove the retainer.
    4. Remove the fuel suction with pump and gauge tube assembly from the fuel tank.
      NOTE: Be careful not to bend the arm of the fuel sender gauge.
    5. Remove the gasket from the fuel tank.
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