Fuel Tank: Removal

REMOVE REAR CONSOLE BOX SUB-ASSEMBLY
1. Remove the rear console box sub-assembly (See DISASSEMBLY ).
DISCHARGE FUEL SYSTEM PRESSURE (See REMOVAL )
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
REMOVE FUEL TANK CAP ASSEMBLY
DISCONNECT FUEL GAUGE WIRE
1. Disconnect the 2 connectors and detach the clamp.
  
  Fig 1: Locating Fuel Gauge Wire Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connector and clamp.
3. Remove the grommet and pass the sensor connectors out of the cabin through the floor panel.
  
  Fig 2: Locating Grommet And Sensor Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
1. Remove the 2 bolts and disconnect the parking brake cable.
  
  Fig 3: Locating Parking Brake Cable And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. 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-rings 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, kink 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.
2. Disconnect the vent line tube from the fuel tank.
  
  Fig 4: Disconnecting EVAP Hose From Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT AIR INLET LINE TUBE
1. Detach the clamp and disconnect the air inlet line tube from the fuel tank band.
  
  Fig 5: Identifying Air Inlet Line Tube Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL HOSE PROTECTOR
1. Detach the claw and remove the fuel hose protector from the filler pipe hose.
  
  Fig 6: Identifying Fuel Hose Protector And Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FUEL TANK TO FILLER PIPE HOSE
1. Disconnect the filler pipe hose from the fuel tank.
  
  Fig 7: Locating Filler Pipe Hose Clamp Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY
1. Disconnect the breather tube from the fuel tank filler pipe.
  NOTE:
  - Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings 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, kink 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.
    
    Fig 8: Disconnecting Breather Hose From Fuel Tank
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK FILLER PIPE SUB-ASSEMBLY
1. Remove the 3 bolts and filler pipe protector.
2. Remove the 2 bolts and filler pipe.
REMOVE FUEL TANK ASSEMBLY
1. Set a transmission jack underneath the fuel tank.
2. Remove the 6 bolts and 3 fuel tank bands.
3. Slightly lower the transmission jack.
  NOTE: Be careful not to cut the wiring.
  
  Fig 9: Locating Filler Pipe Protector With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Fold back approximately half of any cushion rubber necessary for the detachment of the wire harness from the fuel tank in the step below.
5. Disconnect the fuel pump connector and sender gauge connector.
  NOTE:
  - Before this procedure, check the connector for dirt, mud or other contamination.
  - Do not use any tools in this procedure.
6. Detach the wire harness from the 4 clamps and remove the fuel tank.