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Home >> Toyota >> 2008 >> Yaris Base, 2D Hatchback, Standard >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System >> Fuel Tank >> Removal

Fuel Tank: Removal

NOTE: Always use "Tone" socket wrench E10 when removing the rear seat.
  1. REMOVE REAR SEAT CUSHION COVER PAD (for Hatchback) (See  REMOVAL  ) 
  2. REMOVE REAR SEAT CUSHION COVER PAD (for Sedan) (See  REMOVAL  ) 
  3. REMOVE PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback) (See  REMOVAL  ) 
  4. REMOVE DECK BOARD SUB-ASSEMBLY (for Hatchback) (See  REMOVAL  ) 
  5. REMOVE DECK FLOOR BOX (for Hatchback) (See  REMOVAL  ) 
  6. REMOVE REAR SEAT LEG COVER NO. 1 (for Hatchback) (See  REMOVAL  ) 
  7. REMOVE REAR SEAT LEG COVER NO. 2 (for Hatchback) (See  REMOVAL  ) 
  8. REMOVE REAR SEAT ASSEMBLY (for Hatchback) (See  REMOVAL  ) 
  9. REMOVE REAR FLOOR SERVICE HOLE COVER (See  REMOVAL   ) 
  10. DISCHARGE FUEL SYSTEM PRESSURE (See  PRECAUTION   ) 
  11. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  12. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (See  REMOVAL   ) 
  13. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY (See  REMOVAL   ) 
  14. REMOVE FUEL PUMP GAUGE RETAINER (See  REMOVAL   ) 
  15. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (See  REMOVAL   ) 
  16. DRAIN FUEL 
  17. REMOVE FRONT FLOOR HEAT INSULATOR NO. 4 
    1. Remove the 2 nuts together with the insulator.
      Fig 1: Locating Front Floor Heat Insulator No. 4 Nuts
      G04829109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the bolt together with the clip.
      Fig 2: Locating Fuel Tank Protector Sub-Assembly Bolt
      G04829110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Release the lock as shown in Fig 3, then pull and remove the fuel tank main tube.
      NOTE:
      • Remove any dirt and foreign matter from the clip before performing this work.
      • Avoid any scratches or foreign matter on the parts when disconnecting them, as the quick connector has the 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 them.
      Fig 3: Locating Fuel Tank Main Tube Sub-Assembly
      G04829111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT FUEL TANK BREATHER HOSE 
    1. Release the lock as shown in the illustration, then pull and remove the fuel tank breather hose.
      NOTE:
      • Remove any dirt and foreign matter from the clip before performing this work.
      • Avoid any scratches or foreign matter on the parts when disconnecting, as the quick connector has the 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 them.
      Fig 4: Locating Fuel Tank Breather Hose
      G04829112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY LOWER 
    1. Loosen the clamp and disconnect the fuel tank filler pipe.
      Fig 5: Locating Fuel Tank Filler Pipe Clamp
      G04829113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK ASSEMBLY 
    1. Remove the 4 bolts and remove the fuel tank.
      Fig 6: Locating Fuel Tank Bolts
      G04829114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the fuel tank main tube from the fuel tank.
      Fig 7: Identifying Fuel Tank Main Tube
      G04829115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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