Fuel Tank: Removal

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

DISCHARGE FUEL SYSTEM PRESSURE (See REMOVAL )
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
REMOVE FUEL TANK CAP
REMOVE FRONT FLOOR COVER
1. Remove the nut, bolt, 3 clips and floor cover.
REMOVE NO. 1 FLOOR UNDER COVER
1. Remove the 2 nuts, clip and floor under cover.
  
  Fig 1: Identifying Nuts, Clip And Floor Under Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
1. Remove the 2 bolts and disconnect the parking brake cable.
  
  Fig 2: Identifying Parking Brake Cable Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Pinch and pull the main tube connector to disconnect the connector from the pipe.
  NOTE:
  - Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
  - Do not use any tools to separate the pipe and connector.
  - Do not forcefully bend or twist the nylon tube.
  - Check for foreign matter on the pipe seal surface. Clean if necessary.
  - Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
  - If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
  Fig 3: Identifying Fuel Tank Main Tube Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the EVAP hose from the tank.
DISCONNECT FUEL TANK TO FILLER PIPE HOSE
1. Disconnect the filler pipe hose from the fuel tank.
  
  Fig 4: Identifying Filler Pipe Hose From Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FUEL TANK BREATHER HOSE
1. Disconnect the breather hose from the fuel tank.
  NOTE:
  - Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
  - Do not use any tools to separate the pipe and connector.
  - Do not forcefully bend or twist the nylon tube.
  - Check for foreign matter on the pipe seal surface. Clean if necessary.
  - Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
  - If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
    
    Fig 5: Identifying Breather Hose From Fuel Tank
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK FILLER PIPE
1. Remove the 3 bolts and filler pipe protector.
2. Remove the 2 bolts and filler pipe.
REMOVE FUEL TANK ASSEMBLY
1. Set a mission jack underneath the fuel tank.
2. Remove the 6 bolts and 3 fuel tank bands.
  
  Fig 6: Identifying Fuel Tank Bands Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Slightly lower the mission jack.
  NOTE: Be careful not to cut the wirings.
4. Fold back approximately half of each cushion rubber so that the wire harness can be detached from the fuel tank in the step below.
  
  Fig 7: Identifying Fuel Tank Cushion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the fuel pump connector and sender gauge connector.
  NOTE:
  - Before this procedure, check the connector for dirt, mud or other contamination.
  - Do not use any tools in this procedure.
6. Detach the wire harness from the 4 clamps and remove the fuel tank.