LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2012 >> Prius Five >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Fuel System (Except Plug-In) (Service Information) >> Fuel Tank >> Removal >> Removal

Fuel Tank: Removal: Removal

  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Remove the fuel suction tube assembly with pump and gauge. Refer to REMOVAL .
  2. DRAIN FUEL 
  3. REMOVE REAR FLOOR SIDE MEMBER COVER LH (w/ Floor Under Cover)  . Refer to REMOVAL - Step 11
  4. REMOVE REAR FLOOR SIDE MEMBER COVER RH (w/ Floor Under Cover)  . Refer to REMOVAL - Step 12
  5. REMOVE REAR SUSPENSION BRACE SUB-ASSEMBLY  . Refer to REMOVAL - Step 13
  6. REMOVE REAR FLOOR STEP UNDER COVER SUB-ASSEMBLY (w/ Floor Under Cover)  . Refer to REMOVAL - Step 5
  7. REMOVE NO. 1 FUEL TANK PROTECTOR 
    1. Remove the 3 bolts and the No. 1 fuel tank protector.
      Fig 1: Identifying No. 1 Fuel Tank Protector Bolts
      GTY228753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DISCONNECT FUEL CUT-OFF TUBE 
    1. Disconnect the fuel cut-off tube from the charcoal canister assembly.
      Fig 2: Identifying Fuel Cut-Off Tube
      GTY226951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer

      HINT: 

      Do not remove the retainer.

      NOTE:
      • Remove any dirt or foreign matter on the fuel cut-off tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting them as the fuel cut-off tube connector has an O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the fuel cut-off tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel cut-off tube.
      • If the vent hose connector and pipe are stuck, push and pull on them to release.
  9. DISCONNECT FUEL TANK BREATHER TUBE 
    1. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.
      Fig 3: Identifying Fuel Tank Breather Tube
      GTY223366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Quick Connector
      *3 Pipe
      *4 O-ring
    2. Pull out the fuel tank breather tube.
      NOTE:
      • Check that there is no dirt or foreign matter around the connector before this operation and clean the connector as necessary.
      • It is necessary to prevent dirt or foreign matter from entering the connector. If mud or dirt gets in the connector, the O-rings may not seal properly.
      • Do not use any tools in this operation.
      • Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
  10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Pull the tabs of the retainer to disengage the lock claws and pull it down as shown in the illustration
      Fig 4: Identifying Fuel Tank To Filler Pipe Hose
      GTY231982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
    2. Pull out the fuel tank to filler pipe hose.
      NOTE:
      • Check that there is no dirt or foreign matter around the connector before this operation and clean the connector as necessary.
      • It is necessary to prevent dirt or foreign matter from entering the connector. If dirt or foreign matter gets in the connector, the O-rings may not seal properly.
      • Do not use any tools in this operation.
      • Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
  11. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    Fig 5: Identifying Fuel Tank Main Tube Sub-Assembly
    GTY233373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *1 Retainer
    *2 Quick Connector
    *3 Pipe
    *4 O-ring
    1. Pinch the tabs of the retainer to remove the lock claws and pull it down as shown in the illustration.
    2. Pull out and remove the fuel tank main tube sub-assembly.
      NOTE:
      • Check that there is no dirt or foreign matter around the connector before this operation and clean the connector as necessary.
      • It is necessary to prevent dirt or foreign matter from entering the connector. If dirt or foreign matter gets in the connector, the O-rings may not seal properly.
      • Do not use any tools in this operation.
      • Do not bend, kink or twist the nylon tube. Protect the connector by covering it with a plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully.
  12. REMOVE FUEL TANK ASSEMBLY 
    1. Remove the 2 bolts and disconnect the parking brake cable assembly.
      Fig 6: Identifying Parking Brake Cable Assembly Bolts
      GTY223670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Support the fuel tank using an engine lifter.
      Fig 7: View Of Supporting Fuel Tank With An Engine Lift
      GTY223847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 set bolts of the 2 fuel tank bands.
      Fig 8: Identifying Fuel Tank Banks & Set Bolts
      GTY224676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Lower the engine lifter to remove the fuel tank.
      NOTE:
      • Slowly operate the engine lifter to lower the fuel tank.
      • Do not drop the fuel tank.
      • When removing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.
  13. REMOVE NO. 1 FUEL TANK CUSHION 
    1. Remove the 3 No. 1 fuel tank cushions.
      Fig 9: Identifying No. 1 Fuel Tank Cushion
      GTY292177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Fuel Tank Cushion
  14. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY 
    1. Remove the 2 fuel tank cover vent case sub-assemblies.
      Fig 10: Identifying Fuel Tank Cover Vent Case Sub-Assembly
      GTY291112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals