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Removal [05/2019 - ]: Procedure

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [05/2019 - ]

  2. PRECAUTION 
    NOTE:

    After turning the engine switch is turned off, there may be a waiting time before disconnecting the negative (-) battery terminal.

    Refer to PRECAUTION [05/2019 - ]

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  4. REMOVE FRONT FLOOR COVER CENTER LH 
    GTY516627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt, 2 nuts and 6 clips from the front floor cover center LH.
    2. Loosen the nut and remove the front floor cover center LH.
      GTY521704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 2 FLOOR UNDER COVER 
    1. Detach the clip and loosen the 2 nuts and No. 2 floor under cover.
      GTY516623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. DISCONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Disconnect the connector from the charcoal canister assembly.
      GTY516624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the 3 clamps and disconnect the fuel gauge wire.
    3. Disconnect the fuel tank to canister tube sub-assembly from the charcoal canister assembly.
      GTY516625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [05/2019 - ]

  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the 2 fuel tank main tube sub-assemblies from the 2 fuel pipes.
      GTY516628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [05/2019 - ]

  8. DRAIN FUEL 
    NOTE:
    • When disconnecting the fuel tank to filler pipe hose, fuel remaining in the fuel tank assembly may be discharged.
    • Be aware that fuel discharging cannot be performed if the fuel pump is malfunctioning.
    1. Connect the cable to the negative (-) battery terminal.
    2. Connect the Techstream to the DLC3.
    3. Turn the engine switch on (IG).
    4. Turn the Techstream on.
    5. Enter the following menus: Powertrain / Engine / Active Test / Activate the Circuit Relay

      Powertrain > Engine > Active Test 

      Tester Display
      Activate the Circuit Relay
    6. According to the display on the Techstream, operate the fuel pump and discharge the fuel from the fuel tank main tube sub-assembly.
      WARNING:
      • Do not smoke or be near an open flame when working on the fuel system.
      • Secure good ventilation.
      • Keep gasoline away from rubber or leather parts.
    7. Disconnect the cable from the negative (-) battery terminal.
  9. REMOVE FUEL HOSE PROTECTOR 
    1. Detach the claw and remove the fuel hose protector from the fuel tank to filler pipe hose.
      GTY516629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    NOTE:

    Be careful when discharging the remaining fuel from the fuel tank assembly.

    1. Loosen the hose clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank assembly.
      GTY516630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Detach the clamp and disconnect the fuel tank vent hose sub-assembly from the No. 2 fuel tank band sub-assembly.
      GTY516607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank breather tube sub-assembly from the fuel tank filler pipe sub-assembly.

      Refer to PRECAUTION [05/2019 - ]

      GTY516608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the 3 clamps from the 2 No. 4 fuel tube clamps and the bracket on the vehicle side.
      GTY518834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an engine lifter and attachments, support the fuel tank assembly.
    3. Remove the 2 bolts and No. 1 fuel tank band sub-assembly.
      GTY516605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts and 2 No. 2 fuel tank band sub-assemblies.
    5. Slightly lower the engine lifter.
      NOTE:

      Be careful not to cut the fuel gauge wire.

    6. Disconnect the 2 connectors from the fuel sender gauge assembly and fuel suction tube assembly with pump.
      GTY503563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before starting the operation, check that there is no mud or other dirt on the connector.
      • Do not use any tools.
    7. Detach the 3 clamps from the No. 3 fuel tube clamp, No. 4 fuel tube clamp and No. 5 fuel tube clamp, and disconnect the fuel gauge wire from the fuel tank assembly.
  14. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 

    See step  2

  15. REMOVE FUEL TANK VENT TUBE SET PLATE 

    See step  3

  16. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP 

    See step  4

  17. REMOVE FUEL SENDER GAUGE ASSEMBLY 

    See step  2

  18. REMOVE FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Remove the fuel tank to canister tube sub-assembly from the fuel tank assembly.
      GTY516606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [05/2019 - ]

  19. REMOVE FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Detach the clamp and remove the fuel tank breather tube sub-assembly from the fuel tank assembly.
      GTY521700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [05/2019 - ]

  20. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the 5 clamps and remove the fuel tank main tube sub-assembly from the No. 3 fuel tube clamp, 3 No. 4 fuel tube clamps and No. 5 fuel tube clamp.
      GTY503567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 3 FUEL TUBE CLAMP 
    1. Remove the No. 3 fuel tube clamp from the fuel tank assembly.
  22. REMOVE NO. 4 FUEL TUBE CLAMP 
    1. Remove the 3 No. 4 fuel tube clamps from the fuel tank assembly.
  23. REMOVE NO. 5 FUEL TUBE CLAMP 
    1. Remove the No. 5 fuel tube clamp from the fuel tank assembly.
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