Removal [04/2013 - 08/2015]: Procedure

Refer to REMOVAL [04/2013 - 08/2015] 

Refer to REMOVAL [04/2013 - 08/2015] 

Refer to REMOVAL [04/2013 - 08/2015]

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 5

1. for Half Cover Type:
   1. Remove the 2 protectors from the fuel tank main tube sub-assembly and fuel tank return tube.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Disconnect the fuel tank main tube sub-assembly and fuel tank return tube.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Fuel Pipe
   *b	Retainer
   *c	Nylon Tube
   *d	Fuel Tube Connector
   *e	O-ring
   	Push
   	Pull Out
   	Pull Off

   1. Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
      NOTE:

      • Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.
      • Be sure to disconnect the fuel tube connector by hand.
   2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
      NOTE:

      • Be sure to disconnect the fuel tube connector by hand.
      • 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.
      • Do not forcibly bend, twist or turn nylon tube.
   3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
   4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

1. Loosen the clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   *a	Retainer
   	Pull
   	Pull Off

   NOTE:

   • Remove any dirt or foreign matter on the fuel cut off valve tube before performing this work.
   • 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.
   • Only disconnect the fuel cut off valve tube by hand.
   • Do not forcibly bend, twist or turn the fuel cut off valve tube.
2. Disconnect the fuel cut off valve tube from the No. 1 evaporation tube clamp.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Retainer
   	Pull
   	Pull Out
   	Pull Off

   NOTE:

   • Remove any dirt or foreign matter on the fuel tank breather tube before performing this work.
   • 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.
   • Only disconnect the fuel tank breather tube by hand.
   • Do not forcibly bend, twist or turn the fuel tank breather tube.
2. Disconnect the fuel tank breather tube from the clamp.

1. Remove the 2 bolts, 2 nuts and 4 clamps, and disconnect the No. 2 parking brake cable and No. 3 parking brake cable.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Refer to PROCEDURE - Step 48

Refer to PROCEDURE - Step 49

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   	Bolt
   	Nut

   HINT: 

   Using height adjustable attachments and plate lift attachments, place the fuel tank assembly horizontally.

2. Remove the 2 nuts, 4 bolts and 2 No. 1 fuel tank bands.
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 clamp and remove the fuel tank return tube and fuel tank main tube sub-assembly from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Fuel Tank Return Tube
   *2	Fuel Tank Main Tube Sub-assembly

2. Remove the No. 5 fuel tube clamp from the fuel tank assembly.

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, 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.