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Removal [11/2016 - ]: Procedure

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  1. PRECAUTION 
    NOTE:

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

    Refer to PRECAUTION [11/2016 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2016 - ]

  3. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 1

  4. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [11/2016 - ]

  6. REMOVE CENTER EXHAUST PIPE ASSEMBLY 

    Refer to REMOVAL [11/2016 - ]

  7. REMOVE FRONT CENTER FLOOR COVER 

    Refer to PROCEDURE - Step 1

  8. REMOVE NO. 3 FRONT FLOOR HEAT INSULATOR 
    1. Remove the 4 nuts and No. 3 front floor heat insulator from the vehicle body.
      GTY425070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the screw.
      GTY714582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Grommet
      Screw
    2. Disengage the 4 grommets to remove the No. 1 fuel tank protector sub-assembly from the fuel tank assembly.
  10. DISCONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    1. Remove the bolt and nut and disconnect the No. 3 parking brake cable assembly.
      GTY425071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose sub-assembly from the canister (charcoal canister assembly).
      GTY722153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2016 - ]

    2. Disengage the clamp to disconnect the fuel tank vent hose sub-assembly.
  12. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube sub-assembly from the fuel pipe.
      GTY722159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2016 - ]

  13. DISCONNECT FUEL TANK WIRE 
    1. Disconnect the 2 fuel tank wire connectors.
      GTY722138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp to disconnect the fuel tank wire.
  14. DISCONNECT FUEL TANK BREATHER ELBOW TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank breather elbow tube sub-assembly from the fuel tank assembly.
      GTY722158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2016 - ]

  15. DISCONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Disengage the fuel tank to filler pipe hose from the fuel tank assembly.
      GTY722157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2016 - ]

  16. REMOVE FUEL TANK ASSEMBLY 
    1. Support the fuel tank assembly using an engine lifter.
      GTY731061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Remove the 4 bolts, No. 1 fuel tank band sub-assembly LH and No. 1 fuel tank band sub-assembly RH.
      GTY424728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Lower the engine lifter to remove the fuel tank assembly.
      NOTE:
      • Be careful not to drop the fuel tank assembly.
      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.
  17. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    Refer to REMOVAL [11/2016 - ] 

  18. DRAIN FUEL 
  19. REMOVE FUEL TANK SOLENOID MAIN VALVE ASSEMBLY 
    1. Disconnect the fuel tank solenoid main valve assembly connector.
      GTY424729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank vent hose sub-assembly from the fuel tank assembly.
      GTY619836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Pinch
      Pull off
      NOTE:
      • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tank vent hose sub-assembly connector has an O-ring that seals the fuel tank assembly.
      • Be sure to disconnect the fuel tank vent hose sub-assembly connector by hand.
      • Do not bend, twist, pinch or kink the fuel tank vent hose sub-assembly.
      • Cover the disconnected fuel tank vent hose sub-assembly with a plastic bag to prevent damage and contamination.
      • If the fuel tank vent hose sub-assembly connector and fuel tank assembly are stuck, push and pull to release them.
      1. Push the fuel tank vent hose sub-assembly firmly toward the fuel tank assembly.
      2. Pinch the fuel tank vent hose sub-assembly as shown in the illustration.
      3. Pull off the fuel tank vent hose sub-assembly.
    3. Remove the 2 nuts and fuel tank solenoid main valve assembly from the fuel tank assembly.
  20. REMOVE FUEL TANK WIRE 
    1. Disengage the 6 clamps to remove the fuel tank wire from the fuel tank assembly.
      GTY657257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disengage the clamp to remove the fuel tank main tube sub-assembly from the fuel tank assembly.
      GTY657261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE NO. 1 FUEL TUBE CLAMP 
    1. Remove the No. 1 fuel tube clamp from the fuel tank assembly.
      GTY657259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE GROMMET 
    1. Remove the grommet from the fuel tank assembly.
      GTY424732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL TANK CUSHION 

    HINT: 

    Perform this procedure only when replacement of the fuel tank cushion is necessary.

    1. Remove the 4 No. 1 fuel tank cushions, No. 2 fuel tank cushion and No. 3 fuel tank cushion from the fuel tank assembly.
      GTY624314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion
      *3 No. 3 Fuel Tank Cushion
    2. Remove the No. 1 fuel tank cushion from the fuel tank assembly.
      GTY682357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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