Removal [08/2013 - 08/2016]: Procedure

• w/ Non-removable Headrest:

  Refer to REMOVAL [08/2013 - ]

• w/ Removable Headrest:

  Refer to REMOVAL [08/2013 - ]

1. Remove the rear floor service hole cover and butyl tape.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Disconnect the fuel pump connector.

Refer to PRECAUTION [08/2013 - 08/2016]

1. Pull out the retainer to disengage the lock claws and pull off the fuel tank vent hose sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Retainer
   	Pull Out
   	Pull Off

   NOTE:

   • Remove any dirt or foreign matter on the fuel tank vent hose sub-assembly before performing this work.
   • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tank vent hose sub-assembly has an O-ring that seals the fuel pipe.
   • Only disconnect the fuel tank vent hose sub-assembly by hand.
   • Do not forcibly bend, twist or turn the fuel tank vent hose sub-assembly.

1. Remove the tube joint clip, and pull off the fuel tube joint of the fuel tank main tube sub-assembly.

   Courtesy 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 allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has O-rings that seal the fuel pipe.
   • Only disconnect the fuel tube joint by hand.
   • Do not forcibly bend, twist or turn the nylon tube.
   • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint.
   • If the fuel tube joint and fuel suction plate sub-assembly are stuck, push and pull to release them.

1. Copy the fully tightened marks and start of threads mark of the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Copy of Fully Tightened Mark
   *b	Copy of Start of Threads Mark
   *c	Fully Tightened Mark on Fuel Tank Assembly
   *d	Start of Threads Mark on Fuel Tank Assembly

   1. Copy the start of threads mark (1 triangle mark) and fully tightened mark (2 triangle marks) from the fuel tank assembly to the surrounding vehicle body in order to record their locations.
2. Install SST to the fuel pump gauge retainer.
   1. Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.
      • SST: 09808-14030 
        1. 09808-01030
        2. 09808-01050
      • SST: 09808-01071 

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *1	Fuel Pump Gauge Retainer
      *a	SST (Claw)
      *b	Narrow
      *c	Wide
      *d	Correct
      *e	Incorrect

      NOTE:

      • Install SST (claw) to the correct location.
      • Do not install SST (claw) to a location where the pitch between ribs of the fuel pump gauge retainer is narrow.
   2. Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Center Point of Fuel Pump Gauge Retainer

   3. Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).
   4. Install SST (handle).
      NOTE:

      The torque required to remove the fuel pump gauge retainer may be as high as 200 N*m (2039 kgf*cm, 148 ft.*lbf) due to swelling of the fuel tank assembly, so perform the procedure with 2 people.

3. While holding down the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle), and while another person pulls the opposite end of SST (handle), slowly loosen the fuel pump gauge retainer by approximately 90°.
   • SST: 09808-14030 
     1. 09808-01010
     2. 09808-01020
     3. 09808-01030
     4. 09808-01050
   • SST: 09808-01071 
   NOTE:

   • Be careful not to apply excessive downward force to SST, as this may damage the fuel pump or fuel tank assembly.
   • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so be sure SST is horizontal when turning.
   • To prevent damage to parts, do not turn SST too vigorously.
   • If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Hold Down
   *b	Pull

4. Continue to slowly loosen the fuel pump gauge retainer while another person is pressing down on the fuel suction tube with pump and gauge assembly to keep the protrusion of the fuel suction tube with pump and gauge assembly engaged with the groove of the tank suction tube support so that the fuel suction tube with pump and gauge assembly does not move out of position.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	One Person in Charge of Loosening
   *b	One Person in Charge of Holding

   NOTE:

   • The fuel suction tube with pump and gauge assembly is pressed against the underside of the fuel tank assembly by a spring, and the constant upward pressure applied by this spring causes the fuel suction tube with pump and gauge assembly to rise up.
   • If the fuel pump gauge retainer is turned while the fuel suction tube with pump and gauge assembly and fuel tank assembly are not correctly aligned, the fuel suction tube with pump and gauge assembly will move with the fuel pump gauge retainer, and the fuel suction tube with pump and gauge assembly and fuel tank assembly may both be damaged.

1. Remove the fuel suction tube with pump and gauge assembly from the fuel tank assembly.
   NOTE:

   Make sure that the fuel sender gauge arm does not bend.

2. Remove the fuel suction tube set gasket from the fuel tank assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002