Removal [11/2021 - ]: Procedure

Refer to REMOVAL [11/2021 - 09/2022] , or refer to REMOVAL [09/2022 - ] 

Refer to REMOVAL [11/2021 - ] 

Refer to REMOVAL [11/2021 - ]

1. for LH Side:

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

      Refer to PRECAUTION [11/2021 - 09/2022] , or refer to PRECAUTION [09/2022 - ]

2. for RH Side:

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

      Refer to PRECAUTION [11/2021 - 09/2022] , or refer to PRECAUTION [09/2022 - ]

1. Remove the bolt and No. 2 fuel tank filler pipe support from the No. 3 center floor cross member sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the fuel tank to filler pipe hose.
   NOTE:

   Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.

   1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Retainer	*b	O-ring
      *c	Fuel Tube Connector	*d	Fuel Pipe (Fuel Tank Assembly)
      	Pull out		Pull off

   2. If the fuel tube connector and fuel pipe (fuel tank assembly) are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe (fuel tank assembly) carefully.
      NOTE:

      Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe (fuel tank assembly).

   3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
   4. Cover the disconnected fuel pipe (fuel tank assembly) and fuel tube connector with plastic bags to prevent damage and contamination.

1. Pull out the retainer to disengage the lock claws and pull off the fuel cut off valve tube.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Evaporation Vent Tube Clamp
   *a	Retainer
   	Pull
   	Pull off

   NOTE:

   • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel cut off valve tube has an O-ring that seals the pipe.
   • Be sure to disconnect the fuel cut off valve tube by hand.
   • Do not bend, twist, pinch or kink the nylon tube.
2. Disengage the clamp to disconnect the fuel cut off valve tube from the No. 1 evaporation vent tube clamp.

1. Disengage the 2 claws of the retainer. Pull out the retainer and pull off the fuel tank breather tube.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Breather Tube Clamp
   *a	Retainer
   *b	Claw
   	Pull
   	Pull out
   	Pull off

   NOTE:

   • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank breather tube has an O-ring that seals the pipe.
   • Be sure to disconnect the fuel tank breather tube by hand.
   • Do not bend, twist, pinch or kink the nylon tube.
2. Disengage the clamp to disconnect the fuel tank breather tube from the breather tube clamp.

Refer to PROCEDURE - Step 46

Refer to PROCEDURE - Step 47

1. Support the fuel tank assembly using an engine lifter.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

   HINT: 

   Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.
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.

1. Disengage the 2 clamps to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Disengage the 2 clamps to remove the No. 3 fuel tube clamp and No. 5 fuel tube clamp from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 3 Fuel Tube Clamp
   *2	No. 5 Fuel Tube Clamp

1. Remove the 5 No. 6 fuel tank cushions from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Remove the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Fuel Tank Bracket
   *2	Fuel Tank Cushion
   *3	Fuel Tank Cushion Set
   *a	RH Side
   *b	LH Side

1. Remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Fuel Tank Protector Sub-assembly
   *2	No. 2 Fuel Tank Protector
   *3	No. 3 Fuel Tank Protector

2. Remove the No. 2 fuel tank protector and No. 3 fuel tank protector from the fuel tank assembly.