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Fuel Tank: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (See FUEL SYSTEM ).
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE FUEL SUCTION TUBE ASSEMBLY 
    1. Remove the fuel suction tube assembly from the fuel tank assembly (See REMOVAL ).
  4. REMOVE NO. 2 REAR FLOOR SERVICE HOLE COVER (for 4WD)  (See REMOVAL )
  5. REMOVE FUEL SENDER GAUGE RH ASSEMBLY (for 4WD)  (See REMOVAL )
  6. DRAIN FUEL 
  7. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 4WD) 

    HINT.

    See REMOVAL

  8. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2WD) 

    HINT:

    See REMOVAL

  9. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY  (See REMOVAL )
  10. SEPARATE PARKING BRAKE CABLE 
    1. Remove the 4 bolts, and separate the parking brake cables.
    Fig 1: Locating Parking Brake Cables With Bolts
    G06041937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY (for 4WD) 
    1. Remove the 4 bolts and 2 nuts, then remove the fuel tank protector sub-assembly.
    Fig 2: Locating Fuel Tank Protector Bolts And Nut
    G06041938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK PROTECTOR SUB-ASSEMBLY (for 2WD) 
    1. Remove the 4 bolts and the fuel tank protector sub-assembly.
  13. REMOVE CHARCOAL CANISTER ASSEMBLY (for Double Wishbone Type Suspension) 

    HINT:

    Fig 3: Locating Fuel Tank Protector Bolts
    G06009797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY (for Double Wishbone Type Suspension) 

    HINT:

    See REMOVAL

  15. DISCONNECT FUEL TANK VENT HOSE (for Torsion Beam Type Suspension) 
    1. Disconnect the fuel tank vent hose.
      1. Pinch the tabs of the retainer of the fuel tube connector to disengage the lock claws and slide it as shown in the illustration.
      2. Pull the fuel tank vent hose out of the pipe.
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
        • It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes.
        • Protect the connector by covering it with a plastic bag.
        Fig 4: Disconnecting Fuel Tube Connector (Quick Type C)
        G06041811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT BREATHER TUBE FUEL HOSE 
    1. Disconnect the breather tube fuel hose.
      1. Remove the checker of the fuel tube connector from the pipe.
      2. Pinch the retainer of the fuel tube connector, then pull the fuel tube connector out of the pipe.
        Fig 5: Pinching Retainer Of Fuel Tube Connector
        G06041941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
        • It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes.
        • Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
    2. Separate the breather tube fuel hose.
    Fig 6: Locating Breather Tube Fuel Hose
    G06009800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube.
      1. Pinch the tabs of the retainer of the fuel tube connector to disengage the lock claws and push it down as shown in the illustration.
      2. Pull the fuel tank main tube out of the pipe.
        Fig 7: Pinching Tabs Of Retainer Of Fuel Tube Connector
        G06041943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check that there is no dirt or other foreign objects around the connector before disconnecting it. Clean the connector if necessary.
        • It is necessary to prevent mud or dirt from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
        • Only disconnect the quick connector by hand.
        • Do not bend, kink or twist the nylon tubes.
        • Protect the connector by covering it with a plastic bag.
        • If the pipe and connector are stuck, carefully try wiggling or pushing and pulling on the connector to release it. Pull the connector off the pipe carefully.
  18. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Using a screwdriver, unfasten the claw. Then remove the fuel tank filler pipe cover from the fuel tank filler pipe.
      Fig 8: Identifying Fuel Tank Filler Pipe Cover Claw
      G06009802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the hose clamp bolt, then disconnect the fuel tank filler pipe hose from the fuel tank.
    Fig 9: Locating Hose Clamp
    G05193297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL TANK ASSEMBLY (for 4WD) 
    1. Hold the fuel tank using a transmission jack.
      Fig 10: Holding Fuel Tank With Transmission Jack
      G06041946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts, then remove the 2 No. 1 fuel tank bands.
    3. Operate the transmission jack, then remove the fuel tank.
    Fig 11: Locating No. 1 Fuel Tank Bands And Bolts
    G06041947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FUEL TANK ASSEMBLY (for 2WD) 
    1. Hold the fuel tank using a transmission jack.
      Fig 12: Holding Fuel Tank With Transmission Jack
      G06009804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts, then remove the 2 No. 1 fuel tank bands.
    3. Operate the transmission jack, then remove the fuel tank.
    Fig 13: Locating No. 1 Fuel Tank Bands And Bolts
    G06009805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the fuel tank main tube from the fuel tank.
    Fig 14: Locating Fuel Tank Main Tube
    G05193299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK VENT HOSE (for 4WD) 
    1. Remove the fuel tank vent hose.
    Fig 15: Locating Fuel Tank Vent Hose (4WD)
    G06041951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FUEL TANK VENT HOSE (for 2WD) 
    1. Remove the fuel tank vent hose from the fuel tank clamp.
    Fig 16: Locating Fuel Tank Vent Hose (2WD)
    G05193300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE NO. 1 FUEL TANK CUSHION (for 4WD) 
    1. Remove the No. 1 fuel tank cushions from the fuel tank.
    Fig 17: Locating No. 1 Fuel Tank Cushion (4WD)
    G06041953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE NO. 3 FUEL TANK CUSHION (for 4WD) 
    1. Remove the No. 3 fuel tank cushions from the fuel tank.
    Fig 18: Locating No. 3 Fuel Tank Cushion (4WD)
    G06041954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FUEL TANK CUSHION (for 2WD) 
    1. Remove the fuel tank cushions from the fuel tank.
    Fig 19: Locating Fuel Tank Cushion (2WD)
    G06041955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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