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Fuel Tank: Removal: Removal

  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    Refer to REMOVAL 

  2. DRAIN FUEL 
  3. REMOVE REAR FLOOR SIDE MEMBER COVER LH  . Refer to REMOVAL - Step 9
  4. REMOVE REAR FLOOR SIDE MEMBER COVER RH  . Refer to REMOVAL - Step 10
  5. REMOVE REAR SUSPENSION BRACE SUB-ASSEMBLY  . Refer to REMOVAL - Step 11
  6. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to REMOVAL

  7. SEPARATE NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 bolts of the No. 2 parking brake cable assembly.
      Fig 1: Identifying No. 2 Parking Brake Cable Assembly & Bolts
      GTY342579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. SEPARATE NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the 2 bolts of the No. 3 parking brake cable assembly.
      Fig 2: Identifying No. 3 Parking Brake Cable Assembly & Bolts
      GTY342578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 FUEL TANK PROTECTOR 
    1. Remove the 3 bolts and No. 1 fuel tank protector.
      Fig 3: Identifying No. 1 Fuel Tank Protector & Bolts
      GTY342653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 1 FLOOR UNDER COVER 
    1. Disconnect the 3 clamps.
      Fig 4: Identifying No. 1 Floor Under Cover & Clamps
      GTY338945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Remove clamp A as shown in the illustration.

    2. Remove the nut, 5 clips and No. 1 floor under cover.
  11. DISCONNECT FUEL CUT-OFF TUBE 
    1. Pinch the tabs of the retainer to disengage the 2 claws. Pull the retainer as shown in the illustration.
      Fig 5: Identifying Fuel Cut-Off Tube & Claws
      GTY339021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Fuel Cut-off Tube Connector
      Pull Out
      Pinch
      Pull

      HINT: 

      Do not remove the retainer.

    2. Pull out the fuel cut-off tube connector from the charcoal canister assembly.
      NOTE:
      • Remove any dirt or foreign matter on the fuel cut-off tube connector before performing this work.
      • Do not scratch or allow foreign matter to contact 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 tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel cut-off tube connector.
      • If the fuel cut-off tube connector and pipe are stuck, push and pull to release them.
  12. DISCONNECT FUEL TANK BREATHER TUBE 
    1. Pinch the tabs of the retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.
      Fig 6: Identifying Fuel Tank Breather Tube & Claws
      GTY335251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Pipe
      *4 O-ring
      *5 Fuel Tube
      Pull Out
      Pinch
      Pull

      HINT: 

      Do not remove the retainer.

    2. Pull out the fuel tank breather tube from the charcoal canister assembly.
      NOTE:
      • Check that there is no damage or foreign matter around the connecting parts of the fuel tube connector and fuel pipe before performing this work.
      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
      • Only disconnect the fuel tube connector by hand.
      • Do not forcibly bend, twist or turn the fuel tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.
      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.
  13. 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 7: Disconnecting Fuel Tank To Filler Pipe Hose
      GTY328504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pipe
      *2 Retainer
      *3 Connector
      *4 Fuel Tank to Filler Pipe Hose
      Pull Out
      Pull

      HINT: 

      Do not remove the retainer.

    2. Pull out the fuel tank to filler pipe hose.
      NOTE:
      • Check that there is no damage or foreign matter around the connecting parts of the connector and pipe before performing this work.
      • 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 connector by hand.
      • Do not forcibly bend, twist or turn the fuel tank to filler pipe hose.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the connector.
      • If the connector and pipe are stuck, push and pull to release them.
  14. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Pinch the tabs of the retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.
      Fig 8: Removing Fuel Tank Main Tube Sub-Assembly
      GTY338226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Pipe
      *4 O-ring
      Pull Out
      Pinch
      Pull

      HINT: 

      Do not remove the retainer.

    2. Pull out the fuel tank main tube sub-assembly.
      NOTE:
      • Check that there is no damage or foreign matter around the connecting parts of the fuel tube connector and fuel pipe before performing this work.
      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
      • Only disconnect the fuel tube connector by hand.
      • Do not forcibly bend, twist or turn the fuel tube.
      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube connector.
      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.
  15. REMOVE FUEL TANK ASSEMBLY 
    1. Support the fuel tank assembly using an engine lifter.
      Fig 9: Supporting Fuel Tank Using Engine Lifter
      GTY342575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts of the 2 fuel tank bands.
      Fig 10: Identifying Fuel Tank Bands & Bolts
      GTY342574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Lower the engine lifter to remove the fuel tank assembly.
      NOTE:
      • Slowly operate the engine lifter to lower the fuel tank assembly.
      • Do not drop the fuel tank assembly.
      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.
  16. REMOVE NO. 3 FUEL TANK CUSHION 
    1. Remove the 2 No. 3 fuel tank cushions from the fuel tank assembly.
      Fig 11: Identifying Fuel Tank Cushions
      GTY342849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 3 Fuel Tank Cushion
      *2 No. 1 Fuel Tank Cushion
  17. REMOVE NO. 1 FUEL TANK CUSHION 
    1. Remove the 3 No. 1 fuel tank cushions from the fuel tank assembly.
  18. REMOVE UPPER FUEL TANK COVER 
    1. Disconnect the 10 clamps and remove the upper fuel tank cover.
      Fig 12: Identifying Upper Fuel Tank Cover & Clamps
      GTY342655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 FUEL TANK PROTECTOR 
    1. Remove the 3 clips as shown in the illustration, and remove No. 3 fuel tank protector and No. 2 fuel tank protector.
      Fig 13: Identifying Clips & Fuel Tank Protectors
      GTY338017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 3 Fuel Tank Protector
      *2 No. 2 Fuel Tank Protector
  20. REMOVE LOWER FUEL TANK COVER SUB-ASSEMBLY 
    1. Remove the lower fuel tank cover sub-assembly.
      Fig 14: Identifying Lower Fuel Tank Cover Sub-Assembly
      GTY342654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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