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Removal [12/2015 - 08/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (Refer to PRECAUTION [12/2015 - 08/2016] )

  2. REMOVE CHARCOAL CANISTER PROTECTOR 

    Refer to PROCEDURE - Step 1

  3. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Release the fuel tube connector cover as shown in the illustration.
      GTY729682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Fuel Tube Connector Cover
      *3 Fuel Tube Connector
      *4 Fuel Pipe
      *5 O-Ring
      *6 Nylon Tube
      Up
      Pinch
      Pull Out
    2. Pinch the retainer to release it as shown in the illustration and disconnect the fuel tank main tube (Refer to PRECAUTION [12/2015 - 08/2016] ).
      NOTE:
      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      • The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      • Do not use any tools.
      • Do not bend or twist the tubes.
      • Protect the contact surface by covering it with a plastic bag.
      • If the connector is stuck, push and pull on the parts to separate them.
  4. DRAIN FUEL 
    1. Operate the fuel pump and drain the fuel from the fuel tank through the fuel tank main tube (Refer to PROCEDURE - Step 1 ).
  5. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2WD) 
    1. Remove the 4 bolts and 2 compression springs.
      GTY298371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 exhaust pipe supports and remove the center exhaust pipe assembly.
    3. Remove the 2 gaskets from the front exhaust pipe assembly and center exhaust pipe assembly.
  6. REMOVE NO. 1 FUEL TANK HEAT INSULATOR (for 2WD) 
    1. Remove the 4 nuts and No. 1 fuel tank heat insulator.
      GTY441780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) 

    (Refer to REMOVAL [12/2015 - ] )

  8. DISCONNECT FUEL TANK VENT HOSE 

    Refer to PROCEDURE - Step 2

  9. DISCONNECT CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  10. REMOVE REAR FLOOR NO. 2 CROSSMEMBER BRACE LH 
    1. Remove the 2 bolts and the rear floor No. 2 crossmember brace LH.
      GTY437808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FUEL TANK FILLER HOSE COVER 
    1. Remove the 3 bolts and the fuel tank filler hose cover.
      GTY434845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FUEL TANK ASSEMBLY 
    1. Disconnect the fuel tank to filler pipe hose.
      GTY714835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the charcoal canister outlet tube (Refer to PRECAUTION [12/2015 - 08/2016] ).
      GTY434578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Push
      Pinch
      Pull Out
      NOTE:
      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      • The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      • Do not use any tools.
      • Do not bend or twist the tubes.
      • Protect the contact surface by covering it with a plastic bag.
      • If the connector is stuck, push and pull on the parts to separate them.
    3. Pinch the retainer to release it as shown in the illustration and disconnect the fuel tube (Refer to PRECAUTION [12/2015 - 08/2016] ).
      GTY448892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Pipe
      *4 O-Ring
      *5 Nylon Tube
      Pinch
      Pull Out
      NOTE:
      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      • The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      • Do not use any tools.
      • Do not bend or twist the tubes.
      • Protect the contact surface by covering it with a plastic bag.
      • If the connector is stuck, push and pull on the parts to separate them.
    4. Disengage the 2 wire harness clamps.
      GTY434587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using an engine lifter, support the fuel tank assembly.
      GTY454261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 6 set bolts of the 3 fuel tank bands.
      GTY434576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. While operating the engine lifter, disengage the 4 guides for the wire harness and disconnect the fuel pump connector, then remove the fuel tank assembly and the 3 fuel tank bands from the vehicle.
      GTY434575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Widen the tip of the tube joint clip and pull out the clip in the direction indicated by the arrow.
      GTY705923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Tube Joint Clip
      *2 Fuel Tube Connector
      *3 O-Ring
      Pull Out
      Pull
      NOTE:
      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      • The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      • Do not use any tools.
      • Do not bend or twist the tubes.
      • Protect the contact surface by covering it with a plastic bag.
      • If the connector is stuck, push and pull on the parts to separate them.
    2. Disengage the 4 guides and remove the fuel tank main tube sub-assembly.
      GTY441778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY 
    1. Disengage the 4 clamps and remove the charcoal canister outlet tube sub-assembly.
      GTY454298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FUEL TANK VENT HOSE 
    1. Insert a screwdriver with its tip wrapped in protective tape into the quick connector cutout as shown in the illustration, pry up the retainer and disconnect the fuel tank vent hose.
      GTY427417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
      *2 Retainer
      *a Cutout
      NOTE:
      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      • The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      • Do not bend or twist the tubes.
      • Protect the contact surface by covering it with a plastic bag.
      • If the connector is stuck, push and pull on the parts to separate them.
    2. Disengage the 4 clamps and remove the fuel tank vent hose and hose clamp.
      GTY454299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FUEL PUMP GAUGE RETAINER 
    1. Using SST, loosen the retainer.
      GTY435454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09808-14020 
        1. 09808-01410
        2. 09808-01420
        3. 09808-01430
      NOTE:
      • Do not use any tools other than SST.
      • When the retainer is loosened, be careful as the fuel suction with pump and gauge tube assembly will spring upward from the force of the spring.
      • Remove foreign matter around the fuel suction with pump and gauge tube assembly before this operation.

      HINT: 

      Align the ribs of the fuel pump gauge retainer with the tips of SST.

    2. Remove the fuel pump gauge retainer while holding the fuel suction with pump and gauge tube assembly by hand.
  17. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Remove the fuel suction with pump and gauge tube assembly from the fuel tank.
      NOTE:

      Do not bend the arm of the sender gauge.

  18. REMOVE FUEL SUCTION TUBE SET GASKET 
    1. Remove the gasket from the fuel tank.
      GTY441782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL TANK OVERFILL CHECK VALVE ASSEMBLY 
    1. Pinch the retainer to release it as shown in the illustration and disconnect the fuel tube (Refer to PRECAUTION [12/2015 - 08/2016] ).
      GTY444747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Pipe
      *4 O-Ring
      *5 Nylon Tube
      Pinch
      Pull Out
      NOTE:
      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      • The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      • Do not use any tools.
      • Do not bend or twist the tubes.
      • Protect the contact surface by covering it with a plastic bag.
      • If the connector is stuck, push and pull on the parts to separate them.
    2. Pinch the retainer to release it as shown in the illustration and disconnect the fuel tube (Refer to PRECAUTION [12/2015 - 08/2016] ).
      GTY439914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Pipe
      *4 O-Ring
      *5 Nylon Tube
      Pinch
      Pull Out
      NOTE:
      • Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.
      • The fuel tube connector seals with an O-ring. Ensure that there is no damage or foreign matter on the contact surface.
      • Do not use any tools.
      • Do not bend or twist the tubes.
      • Protect the contact surface by covering it with a plastic bag.
      • If the connector is stuck, push and pull on the parts to separate them.
    3. Disengage the hose clamp.
      GTY441769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, loosen the retainer.
      GTY428035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09808-14020 
        1. 09808-01410
        2. 09808-01420
        3. 09808-01430

      HINT: 

      Align the ribs of the fuel pump gauge retainer with the tips of SST.

      NOTE:

      Remove foreign matter around the fuel tank overfill check valve assembly before this operation.

    5. Remove the fuel tank overfill check valve assembly.
  20. REMOVE NO. 1 FUEL SUCTION TUBE SET GASKET 
    1. Remove the gasket from the fuel tank.
      GTY441770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FUEL TANK TO FILLER PIPE HOSE 
    1. Remove the fuel tank to filler pipe hose from the fuel tank.
      GTY441781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FUEL TANK SIDE PLATE 
    1. Remove the nut, bolt, fuel tank side plate and fuel tank bracket sub-assembly.
      GTY441785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 2 FUEL TANK CUSHION 
    1. Remove the 2 No. 2 fuel tank cushions.
      GTY441786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL TANK CUSHION 
    1. Remove the 6 fuel tank cushions.
      GTY454300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FUEL TANK BAND 
    1. Remove the 6 clips and 3 fuel tank bands.
      GTY441783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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