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Removal [11/2016 - ]: Procedure

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  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2016 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2016 - ]

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [11/2016 - ]

  4. REMOVE REAR NO. 1 SEAT ASSEMBLY 

    for Captain Seat Type: Refer to REMOVAL [12/2013 - ]

    for 60/40 Split Seat Type LH Side: Refer to REMOVAL [12/2013 - ]

    for 60/40 Split Seat Type RH Side: Refer to REMOVAL [12/2013 - ]

  5. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 1

  6. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  7. REMOVE DECK SIDE TRIM BOX LH 

    Refer to PROCEDURE - Step 3

  8. REMOVE REAR DECK FLOOR BOX 

    Refer to PROCEDURE - Step 4

  9. REMOVE REAR FLOOR FINISH PLATE 

    Refer to PROCEDURE - Step 5

  10. REMOVE REAR NO. 2 SEAT ASSEMBLY 

    Refer to REMOVAL [11/2016 - ]

  11. REMOVE REAR OUTER SEAT TRACK BRACKET COVER LH 

    Refer to PROCEDURE - Step 4

  12. REMOVE REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 12

  13. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 

    Refer to PROCEDURE - Step 13

  14. REMOVE REAR OUTER SEAT TRACK BRACKET COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  15. REMOVE REAR DOOR SCUFF PLATE RH 

    HINT: 

    Use the same procedure as for the LH side.

  16. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 

    HINT: 

    Use the same procedure as for the LH side.

  17. REMOVE FRONT DECK SIDE TRIM COVER LH 

    Refer to PROCEDURE - Step 27

  18. DISCONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 11

  19. REMOVE NO. 2 DECK SIDE TRIM COVER 

    Refer to PROCEDURE - Step 29

  20. REMOVE DECK TRIM SIDE SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 30

  21. DISCONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY LH 

    Refer to PROCEDURE - Step 14

  22. REMOVE DECK TRIM POCKET COVER (for LH Side) 

    Refer to PROCEDURE - Step 32

  23. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for LH Side) 

    Refer to PROCEDURE - Step 33

  24. REMOVE ROPE HOOK (for LH Side) 

    Refer to PROCEDURE - Step 34

  25. REMOVE DECK TRIM SIDE PANEL ASSEMBLY LH 

    Refer to PROCEDURE - Step 35

  26. REMOVE FRONT DECK SIDE TRIM COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  27. DISCONNECT REAR NO. 1 SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  28. REMOVE NO. 1 DECK SIDE TRIM COVER 

    Refer to PROCEDURE - Step 40

  29. REMOVE DECK TRIM SIDE BELT HOLE COVER RH 

    Refer to PROCEDURE - Step 41

  30. DISCONNECT REAR NO. 2 SEAT OUTER BELT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  31. REMOVE SIDE TRIM COVER RH (w/o Rear Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 43

  32. REMOVE COOLER (NO. 2 ROOM TEMP. SENSOR) THERMISTOR (w/ Rear Automatic Air Conditioning System) 

    Refer to PROCEDURE - Step 1

  33. REMOVE NO. 1 LUGGAGE COMPARTMENT LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  34. REMOVE DECK TRIM POCKET COVER (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  35. REMOVE NO. 1 LUGGAGE COMPARTMENT TRIM HOOK (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  36. REMOVE ROPE HOOK (for RH Side) 

    HINT: 

    Use the same procedure as for the LH side.

  37. REMOVE DECK TRIM SIDE PANEL ASSEMBLY RH 

    Refer to PROCEDURE - Step 49

  38. REMOVE REAR FLOOR SERVICE HOLE COVER 
    1. Turn back the front floor carpet.
      GTY437483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.
      GTY656370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Disconnect the 2 fuel pump connectors.
  39. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.
      GTY684087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Suction Plate Sub-assembly
      *2 Tube Joint Clip
      *a Fuel Tube Joint
      *b O-ring
      *c Nylon Tube
      Pull off
      Pull off
      NOTE:
      • Remove any foreign matter on the fuel tube joint before performing this work.
      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
      • Be sure to disconnect the fuel tube joint by hand.
      • Do not bend, twist, pinch or kink the nylon tube.
      • Cover the disconnected fuel tube joint with a plastic bag to prevent damage and contamination.
      • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.
  40. REMOVE FUEL PUMP GAUGE RETAINER 
    NOTE:

    Before performing these procedures, first cover the connectors and fuel tube joint of the fuel suction tube with pump and gauge assembly with vinyl tape and then clean any dirt and foreign matter in order to prevent contamination of the fuel system.

    1. Install SST (fuel pump holding tool assy) to the fuel pump gauge retainer.
      1. Insert SST (claw No. 1) between the service hole and fuel pump gauge retainer as shown in the illustration.
        GTY671136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b Wide
        • SST: 09808-14050 
          1. 09882-14050
      2. Align the detent of the tank suction tube support and cutout of SST (claw No. 1).
        GTY666691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b Detent of Tank Suction Tube Support
        Front - -
      3. Insert SST (claw) between the service hole and fuel pump gauge retainer as shown in the illustration.
        GTY611796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b SST (Claw)
        • SST: 09808-14040 
          1. 09882-14040
      4. Insert SST (claw No. 2) between the service hole and fuel pump gauge retainer, and align it with the second detent of the tank suction tube support.
        GTY620284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b SST (Claw No. 2)
        *c SST (Bridge) *d SST (Bolt)
        *e Narrow *f Contact
        *g Cloth *h Detent of Tank Suction Tube Support
        • SST: 09808-14050 
          1. 09881-14050
          2. 09882-14050
          3. 09883-14050
          4. 09884-14050
      5. Install SST (bridge) to SST (claw No. 1) and SST (claw No. 2) with 2 SST (bolt).
      6. Place a piece of cloth or equivalent on the fuel suction tube with pump and gauge assembly and lightly tighten 2 SST (bolt) of SST (bridge) until they come into contact with the fuel suction tube with pump and gauge assembly.
        NOTE:

        If a piece of cloth or equivalent is not placed between the fuel suction tube with pump and gauge assembly and 2 SST (bolt), the fuel suction tube with pump and gauge assembly may be damaged.

    2. Install SST (fuel pump retainer tool assy) to the fuel pump gauge retainer.
      1. Position SST (claw) next to SST (claw No. 1) so that the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw). Insert the second SST (claw) between the service hole and fuel pump gauge retainer, and position it next to SST (claw No. 2) so that it is opposite to SST (claw), and the protrusions of the fuel pump gauge retainer are aligned with the grooves of SST (claw).
        GTY630080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1) *b SST (Claw No. 2)
        *c SST (Claw) *d SST (Bridge)
        *e Triangle Mark *f Protrusion of Fuel Pump Gauge Retainer
        *g Groove of SST (Claw) *h Correct
        *i Incorrect - -
        • SST: 09808-14040 
          1. 09882-14040
        NOTE:

        Ensure that SST (claw) does not cover the triangle mark of the fuel pump gauge retainer.

      2. While ensuring that SST (plate) is centered, install SST (plate) to 2 SST (claw) with 2 SST (bolt and washer set).
        GTY636144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a SST (Claw No. 1)
        *b SST (Claw No. 2)
        *c SST (Claw)
        *d SST (Bridge)
        *e SST (Plate)
        *f SST (Bolt and Washer Set)
        • SST: 09808-14040 
          1. 09881-14040
          2. 09883-14040
    3. Attach 2 breaker bars to SST (fuel pump holding tool assy) and 1 breaker bar to SST (fuel pump retainer tool assy).
      GTY669599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Fuel Pump Holding Tool Assy)
      *b SST (Fuel Pump Retainer Tool Assy)
    4. Place paint marks on the fuel suction tube with pump and gauge assembly, fuel pump gauge retainer and fuel tank assembly as shown in the illustration.
      GTY617386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
    5. While holding the 2 breaker bars attached to SST (fuel pump holding tool assy), turn the breaker bar attached to SST (fuel pump retainer tool assy) to loosen the fuel pump gauge retainer. [*1]
      GTY695699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Fuel Pump Holding Tool Assy) *b SST (Fuel Pump Retainer Tool Assy)
      *c Holding *d Push down
      *e Turn - -
      NOTE:

      Push down on the 2 locations shown in the illustration to prevent SST (fuel pump holding tool assy) from turning.

    6. Check that only the paint mark on the fuel pump gauge retainer has moved.
      GTY632843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b Correct
      *c Incorrect - -

      HINT: 

      If the paint mark on the fuel suction tube with pump and gauge assembly has also moved, tighten the fuel pump gauge retainer until the paint marks are aligned at the original position. Then repeat from step [*1].

    7. Loosen the fuel pump gauge retainer by using SST (fuel pump retainer tool assy) until the fuel pump gauge retainer turns approximately 360°.
      GTY641516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Claw) *b SST (Fuel Pump Holding Tool Assy)
      *c SST (Fuel Pump Retainer Tool Assy) - -
    8. Remove SST (fuel pump retainer tool assy) and SST (fuel pump holding tool assy) from the fuel pump gauge retainer.
    9. Check that the fuel pump gauge retainer can be loosened by hand.

      HINT: 

      If the fuel pump gauge retainer cannot be loosened by hand, use SST (fuel pump retainer tool assy) to loosen the fuel pump gauge retainer.

      GTY648687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Fuel Pump Retainer Tool Assy) - -
      • SST: 09808-14040 
        1. 09881-14040
        2. 09882-14040
        3. 09883-14040
    10. While holding the fuel suction tube with pump and gauge assembly by hand, remove the fuel pump gauge retainer.
  41. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 
    1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge assembly.

    2. Remove the fuel suction tube set gasket from the fuel tank assembly.
      GTY449718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Suction Tube Set Gasket
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