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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 14 (Fuel System (1AR-FE) (Service Information) (Except Hybrid)) >> Fuel Tank >> Removal [12/2013 - 11/2016] >> Procedure

Removal [12/2013 - 11/2016]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    Refer to REMOVAL [12/2013 - ] 

  2. DRAIN FUEL 
  3. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY 

    Refer to REMOVAL [12/2013 - 11/2015] , or refer to REMOVAL [11/2015 - 11/2016]

  4. REMOVE FRONT CENTER FLOOR COVER 
    1. Remove the 2 screws and nut.
      GTY430580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Screw
      Nut
    2. Disengage the 4 clips to remove the front center floor cover.
  5. REMOVE CHARCOAL CANISTER PROTECTOR 

    Refer to PROCEDURE - Step 2

  6. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Remove the 4 clips, 7 nuts and No. 1 fuel tank protector sub-assembly.
      GTY455326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube sub-assembly.
      GTY454577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      *b O-ring
      *c Fuel Tube Connector
      *d Fuel Pipe
      Pull Out
      Pull Off
      1. Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
        NOTE:
        • Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.
        • Be sure to disconnect the fuel tube connector by hand.
      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
      3. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
  8. DISCONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel tank vent hose sub-assembly from the canister (charcoal canister assembly).
      GTY448855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pinch
      Pull
      Pull Off
      NOTE:
      • Remove any dirt or foreign matter on the tube connector before performing this work.
      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the tube connector has an O-ring that seals the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the fuel tank vent hose sub-assembly.
      • Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tank vent hose sub-assembly.
      • If the tube connector and pipe are stuck, push and pull to release them.

      HINT: 

      Do not remove the retainer.

      1. Pinch the tabs of the retainer to disengage the lock claws and pull it down as shown in the illustration.
      2. Pull off the fuel tank vent hose sub-assembly.
  9. DISCONNECT FUEL TANK BREATHER TUBE 
    1. Disconnect the fuel tank breather tube.
      NOTE:

      Remove any dirt or foreign matter on the fuel tube connector and fuel pipe before performing this work.

      1. Pull off the fuel tube connector cover.
        GTY440509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuel Tube Connector Cover *b Retainer
        *c O-ring *d Fuel Tube Connector
        *e Fuel Pipe *f Nylon Tube
        Pinch Pull Off
      2. Check that there is no dirt or other foreign matter around the fuel tube connector before disconnecting it. Clean the joint if necessary.
      3. Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.
        NOTE:

        Be sure to disconnect the fuel tube connector by hand.

      4. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.
        NOTE:
        • Be sure to disconnect the fuel tube connector by hand.
        • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.
        • Do not forcibly bend, twist or turn the nylon tube.
      5. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
      6. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
  10. REMOVE FUEL TANK ASSEMBLY 
    1. Loosen the clamp, then disconnect the fuel tank to filler pipe hose from the fuel tank to filler pipe sub-assembly.
      GTY446878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank To Filler Pipe Hose
      *2 Fuel Tank To Filler Pipe Sub-assembly
    2. Remove the bolt, nut and rear fuel tank bracket LH.
      GTY446562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut.
      GTY446557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Support the fuel tank assembly using an engine lifter.
      GTY455329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Using height adjustment attachments and plate lift attachments, place the fuel tank assembly horizontally.

    5. Remove the 4 bolts, No. 1 fuel tank band sub-assembly LH and No. 1 fuel tank band sub-assembly RH.
    6. Lower the engine lifter to remove the fuel tank assembly.
      NOTE:
      • Do not drop the fuel tank assembly.
      • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the other surrounding parts.
  11. REMOVE FUEL TANK SIDE PLATE 
    1. Remove the fuel tank band pin, fuel tank cushion and fuel tank side plate from the fuel tank assembly.
      GTY437227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank Band Pin
      *2 Fuel Tank Cushion
  12. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disengage the 3 claws to remove the fuel tank main tube sub-assembly from the fuel tank assembly.
      GTY442891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank Main Tube Sub-assembly
  13. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Loosen the clamp, then remove the fuel tank to filler pipe hose from the fuel tank assembly.
      GTY446558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FUEL TANK CUSHION SET 
    1. Remove the 2 fuel tank cushion sets and 2 No. 5 fuel tank cushions from the fuel tank assembly.
      GTY449883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Tank Cushion Set
      *2 No. 5 Fuel Tank Cushion
  15. REMOVE TANK SUCTION TUBE SUPPORT 
    1. Remove the tank suction tube support from the fuel tank assembly.
      GTY446560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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