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Fuel Tank: Removal

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Remove the fuel suction tube assembly with pump and gauge (See REMOVAL ).
  2. DRAIN FUEL 
  3. REMOVE CENTER FRONT FLOOR COVER  (See REMOVAL )
  4. REMOVE TAIL EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  5. REMOVE CENTER EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  6. REMOVE NO. 4 EXHAUST PIPE SUPPORT BRACKET 
    1. Remove the 2 bolts, and then remove the No. 4 exhaust pipe support bracket.
  7. REMOVE NO. 3 FRONT FLOOR HEAT INSULATOR  (See REMOVE )
    Fig 1: Locating No. 4 Exhaust Pipe Support Bracket Bolts
    G05414862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the 3 clips (A) and 7 nuts, and then remove the No. 1 fuel tank protector sub-assembly.
    Fig 2: Locating No. 1 Fuel Tank Protector Sub-Assembly Clips And Nuts
    G05414863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel pump tube.
      1. Pinch the tab of the retainer to disengage the lock claws and pull it down as shown in the illustration.
      2. Pull out the fuel pump tube.
      NOTE:
      • Check if there is any dirt or mud around the connector before this operation and clean the connector if necessary.
      • It is necessary to prevent mud or dirt from entering the quick connector. If any foreign objects enter the connector, the O-rings may not seal properly.
      • Do not use any tools in this operation.
      • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release it and pull the connector out carefully.
      Fig 3: Disconnecting Fuel Pump Tube
      G05414864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank vent hose from the charcoal canister assembly.
      1. Pinch the retainer and pull out the quick connector while pushing the quick connector against the pipe to disconnect the fuel tank vent hose from the charcoal canister assembly.
      Fig 4: Disconnecting Fuel Tank Vent Hose From Charcoal Canister Assembly
      G05414865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove dirt or foreign objects on the quick connector before this work.
      • Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel hose connector has the O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the connected part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
      • If the quick connector and pipe are stuck, push and pull them to release.
    3. Disconnect the No. 3 fuel tank breather tube.
      1. Pinch the tube connector and then pull out the No. 3 fuel tank breather tube.
      NOTE:
      • Check if there is any dirt or mud around the connector before this operation and clean the connector as necessary.
      • It is necessary to prevent mud or dirt from entering the quick connector. If any foreign objects enter the connector, the O-rings may not seal properly.
      • Do not use any tools in this operation.
      • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release it and pull the connector out carefully.
      Fig 5: Pinching Tube Connector And Pulling Out No. 3 Fuel Tank Breather Tube
      G06113088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose.
    5. Set a transmission jack under the fuel tank.
    6. Remove the 4 bolts, and then remove the 2 fuel tank bands.
    7. Remove the 2 nuts.
      Fig 6: Locating Hose Clamp Bolt
      G06113089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Operate the transmission jack to remove the fuel tank.
    Fig 7: Locating Fuel Tank Assembly Bolts, Nuts And Fuel Tank Bands
    G05414868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE REAR FUEL TANK SIDE PLATE 
    1. Remove the rear fuel tank side plate.
    Fig 8: Identifying Rear Fuel Tank Side Plate
    G05414869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 FUEL TANK CUSHION 
    1. Remove the No. 1 fuel tank cushion.
    Fig 9: Identifying No. 1 Fuel Tank Cushion
    G05414870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Release the 2 claws, and then remove the fuel pump tube.
    Fig 10: Identifying Fuel Pump Tube Claws
    G05414871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the hose clamp bolt, and then remove the fuel tank to filler pipe hose.
    Fig 11: Locating Hose Clamp Bolt
    G05414872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL TANK VENT HOSE 
    1. Disconnect the fuel tank vent hose from the fuel tank over fill check valve assembly.
      1. Pinch the retainer and pull out the quick connector while pushing the quick connector against the pipe to disconnect the fuel tank vent hose from the fuel tank over fill check valve assembly.
      Fig 12: Disconnecting Fuel Tank Vent Hose From Fuel Tank Over Fill Check Valve Assembly
      G06113095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Remove dirt or foreign objects on the quick connector before this work.
      • Do not allow any scratches or foreign objects on the parts when disconnecting as the fuel hose connector has the O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the connected part by covering it with a plastic bag after disconnecting the fuel tank vent hose.
      • If the quick connector and pipe are stuck, push and pull them to release.
    2. Disconnect the No. 1 evaporation vent tube.
      NOTE:
      • Check if there is any dirt or mud around the connector before this operation and clean the connector as necessary.
      • It is necessary to prevent mud or dirt from entering the quick connector. If any foreign objects enter the connector, the O-rings may not seal properly.
      • Do not use any tools in this operation.
      • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.
      • When the pipe and connector are stuck, push and pull the connector to release it and pull the connector out carefully.
      Fig 13: Disconnecting No. 1 Evaporation Vent Tube
      G05414874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSEMBLY 
    1. Using a 6 mm socket hexagon wrench, install SST to the fuel pump gauge retainer.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      HINT:

      • Engage the SST claws securely with the fuel pump gauge retainer ribs to secure SST.
      • Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST).
      Fig 14: Installing SST To Fuel Pump Gauge Retainer
      G05414875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, loosen the fuel pump gauge retainer.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      NOTE: Loosen the retainer by turning it counterclockwise while holding SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.
      Fig 15: Loosening Fuel Pump Gauge Retainer
      G05414876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

    3. Remove the fuel pump gauge retainer.
    4. Remove the fuel tank over fill check valve assembly and gasket.
      Fig 16: Identifying Fuel Tank Over Fill Check Valve Assembly And Gasket
      G05414877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the tank suction tube support from the fuel tank.
    Fig 17: Identifying Tank Suction Tube Support And Fuel Tank
    G05414878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE TANK SUCTION TUBE SUPPORT 
    1. Remove the tank suction tube support from the fuel tank.
    Fig 18: Identifying Tank Suction Tube Support
    G05414879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FUEL TANK SIDE PLATE 
    1. Remove the bolt and nut, and then remove the fuel tank side plate and fuel tank bracket.
    Fig 19: Identifying Fuel Tank Side Plate And Fuel Tank Bracket
    G05414880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL TANK CUSHION SET 
    1. Remove the fuel tank cushion sets and No. 5 fuel tank cushions.
    Fig 20: Identifying Fuel Tank Cushion Set And No. 5 Fuel Tank Cushions
    G05414881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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