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Removal & Installation and Disassembly & Reassembly

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM (3MZ-FE)   ) 
  2. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) 
  3. REMOVE REAR SEAT CUSHION ASSY (See  OVERHAUL  ) 
  4. REMOVE REAR FLOOR SERVICE HOLE COVER (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  5. REMOVE FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  6. DRAIN FUEL 
  7. REMOVE FLOOR PANEL BRACE REAR (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  8. REMOVE EXHAUST PIPE ASSY CENTER 
    1. Remove the 2 bolts and 4 nuts.
    2. Remove the exhaust pipe center and 2 gaskets from the 2 exhaust pipe supports.
      Fig 1: Removing Exhaust Pipe Assy Center
      G00906919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. DISCONNECT PARKING BRAKE CABLE ASSY NO.2 
    1. Remove the bolt and nut, then disconnect the parking brake cable No. 2.
      Fig 2: Disconnecting Parking Brake Cable No. 2
      G00906920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT PARKING BRAKE CABLE ASSY NO.3 
    1. Remove the bolt and nut, then disconnect the parking brake cable No. 3.
      Fig 3: Disconnecting Parking Brake Cable No. 3
      G00906921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL TANK PROTECTOR LOWER CENTER 
    1. Remove the 4 bolts, then remove the fuel tank protector lower center.
      Fig 4: Removing Fuel Tank Protector Lower Center
      G00906922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK ASSY 
    1. Disconnect the fuel pump tube.
      1. Pinch the projection of the retainer to remove the lock claws, then pull it down as shown in Fig 5.
      2. Pull out the fuel pump tube.
        Fig 5: Pulling Out Fuel Pump Tube
        G00906923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
        • Be careful of mud because the quick connector has an O-ring which seals the pipe and quick connector that can be contaminated.
        • Do not use any tools in this operation.
        • Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
        • When the pipe and quick connector are stuck, push and pull the quick connector to release. Pull out the quick connector from the pipe.
          Fig 6: Checking Quick Connector
          G00906924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube No. 1.
      1. Pinch the tube connector, then pull out the fuel tube No. 1.
        Fig 7: Pulling Out Fuel Tube No. 1
        G00906925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check around the quick connector for dirt or mud before this operation. Remove the dirt if necessary.
        • Be careful of mud because the quick connector has an O-ring which seals the pipe and quick connector that can be contaminated.
        • Do not use any tools in this operation.
        • Do not bend or twist the nylon tube. Protect the quick connector by covering it with a vinyl or plastic bag.
        • When the pipe and quick connector are stuck, push and pull the quick connector to release. Pull out the quick connector carefully.
          Fig 8: Checking Quick Connector For Dirt
          G00906926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set up a transmission jack underneath the fuel tank.
    4. Remove the 2 bolts which hold the fuel tank bands.
    5. Loosen the clamp bolt.
    6. Operate the transmission jack, then disconnect the fuel tank inlet pipe.
    7. Disconnect the fuel tank vent hose from the charcoal canister.
      1. Deeply push the quick connector to release the lock pin.
      2. Pinch portion A.
      3. Pull out the fuel tank vent hose.
    8. Operate the transmission jack, then remove the fuel tank.
      Fig 9: Removing Fuel Tank
      G00906927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 pins, then remove the 2 fuel tank bands as shown in Fig 10.
      Fig 10: Removing Fuel Tank Bands
      G00906928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the 4 clip nuts.
      Fig 11: Removing Clip Nuts
      G00906929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK VENT HOSE 
    1. Deeply push the quick connector to release the lock pin.
    2. Pinch portion A.
    3. Pull out the fuel tank vent hose.
      Fig 12: Pulling Out Fuel Tank Vent Hose
      G00906930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL PUMP TUBE SUB-ASSY 
    1. Remove the fuel pump tube from the fuel main tube support.
      Fig 13: Removing Fuel Pump Tube From Fuel Main Tube Support
      G00906931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL MAIN TUBE SUPPORT 
    1. Remove the bolt, then remove the fuel main tube support.
      Fig 14: Removing Fuel Main Tube Support
      G00906932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL TANK CUSHION NO.2 
    1. Remove the 7 fuel tank cushions from the fuel tank.
      Fig 15: Removing Fuel Tank Cushions From Fuel Tank
      G00906933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FUEL TANK CUSHION NO.2 
    1. Install 7 new fuel tank cushions to the fuel tank.
  18. INSTALL FUEL MAIN TUBE SUPPORT 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  19. INSTALL FUEL PUMP TUBE SUB-ASSY 
  20. INSTALL FUEL TANK VENT HOSE 
    1. Push in the quick connector to the pipe until the quick connector makes a "click" sound.
      Fig 16: Pushing In Quick Connector To Pipe
      G00906934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check the connected part for damage or foreign objects.
      • After connecting, check if the quick connector and pipe are securely connected by pulling on them.
  21. INSTALL FUEL TANK ASSY 
    1. Install the 4 clip nuts.
    2. Install the 2 fuel tank bands with the 2 pins.
    3. Set up the fuel tank to the transmission jack.
    4. Connect the fuel tank vent hose to the charcoal canister.
      1. Push in the quick connector to the pipe until the quick connector makes a "click" sound.
        Fig 17: Pushing In Quick Connector To Pipe
        G00906935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check the connected part for damage or foreign objects.
        • After connecting, check if the connector and pipe are securely connected by pulling on them.
    5. Operate the transmission jack, then connect the fuel tank filler pipe.
    6. Tighten the clamp bolt.
    7. Tighten the 2 bolts which hold the fuel tank bands.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

    8. Connect the fuel tube No. 1.
      1. Push in the quick connector to the pipe until the quick connector makes a "click" sound.
        Fig 18: Pushing In Quick Connector To Pipe
        G00906936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check the connected part for damage or foreign objects.
        • After connecting, check if the quick connector and pipe are securely connected by pulling on them.
  22. Connect the fuel pump tube.
    1. Push in the quick connector to the pipe until the quick connector makes a "click" sound, then push up the retainer until the claws lock.
      Fig 19: Connecting Fuel Pump Tube
      G00906937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check the connected part for damage or foreign objects.
      • After connecting, check if the connector and pipe are securely connected by pulling on them.
  23. INSTALL FUEL TANK PROTECTOR LOWER CENTER 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  24. INSTALL PARKING BRAKE CABLE ASSY NO.3 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  25. INSTALL PARKING BRAKE CABLE ASSY NO.2 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  26. INSTALL EXHAUST PIPE ASSY CENTER 
    1. Install 2 new gaskets and the exhaust pipe center to the 2 exhaust pipe supports.
    2. Tighten the 2 bolts and 4 new nuts.

    Torque: 56 N.m (571 kgf.cm, 41 ft.lbf) 

  27. INSTALL FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  28. ADD FUEL 
  29. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL) 

    Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

  30. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION   ) 
  31. CHECK FOR EXHAUST GAS LEAKS 
  32. INSTALL REAR FLOOR SERVICE HOLE COVER (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY   ) 
  33. INSTALL REAR SEAT CUSHION ASSY 
  34. INSTALL FLOOR PANEL BRACE REAR (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  35. SYSTEM INITIALIZATION (See  PRECAUTION  ) 
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