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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTFUEL DELIVERY AND AIR INDUCTIONFUEL TANKSERVICE AND REPAIR
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
Fuel Tank: Service and Repair
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION Service and Repair
FUEL TANK ASSY
Removal & Installation and Disassembly & Reassembly
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE REAR SEAT ASSY RH
3. REMOVE REAR SEAT ASSY LH
4. REMOVE REAR FLOOR SERVICE HOLE COVER
5. REMOVE FUEL PUMP TUBE SUB-ASSY
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. REMOVE FUEL SUCTION W/PUMP & GAGE
8. DRAIN FUEL
9. REMOVE EXHAUST PIPE ASSY CENTER
10. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
11. REMOVE FUEL TANK PROTECTOR NO.1
12. REMOVE FUEL TANK PROTECTOR NO.2
13. REMOVE FUEL TANK PROTECTOR LOWER CENTER
14. SEPARATE PARKING BRAKE CABLE ASSY NO.2
a. Remove the parking brake cable.
b. Remove the front floor brace RH
15. SEPARATE PARKING BRAKE CABLE ASSY NO.3
a. Remove the parking brake cable.
b. Remove the front floor brace LH
16. SEPARATE FUEL TANK TO FILLER PIPE HOSE
17. SEPARATE BREATHER TUBE FUEL HOSE
18. SEPARATE FUEL HOSE SUB-ASSY NO.3
19. SEPARATE FUEL CUT OFF W/TUBE VALVE ASSY
20. SEPARATE FUEL TANK VENT HOSE
21. REMOVE FUEL TANK ASSY
a. Remove the 4 bolts and fuel tank.
22. REMOVE FUEL SENDER GAGE ASSY
a. Remove the 6 screws and fuel sender gage.
23. REMOVE FUEL TANK BREATHER TUBE SUB-ASSY
a. Remove the 4 screws, nut and fuel tank breather tube.
24. REMOVE FUEL CUT OFF VALVE ASSY
a. Remove the 4 screws, retainer and fuel cut off valve.
25. REMOVE FUEL CUT OFF VALVE ASSY NO.2
a. Remove the 4 screws, retainer and fuel cut off valve No.2.
26. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY
a. Remove the 6 screws and fuel tank over fill check valve.
27. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY
a. Install a new gasket and the fuel tank over fill check valve.
28. INSTALL FUEL CUT OFF VALVE ASSY NO.2
a. Insert the fuel cut off valve No.2 to the fuel tank.
b. Install the retainer with 4 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
29. INSTALL FUEL CUT OFF VALVE ASSY
a. Insert the fuel cut off valve to the fuel tank.
b. Install the retainer with the 4 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
30. INSTALL FUEL TANK BREATHER TUBE SUB-ASSY
a. Install a new gasket and fuel tank breather tube.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
31. INSTALL FUEL SENDER GAGE ASSY
a. Install a new gasket and the fuel sender gauge.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
32. INSTALL FUEL TANK CUSHION NO.1
a. Install the new fuel tank cushion as shown in the illustration.
33. INSTALL FUEL TANK ASSY
a. Install the fuel tank with 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
34. INSTALL PARKING BRAKE CABLE ASSY NO.2
a. Install the front floor brace RH.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
b. Install the parking brake cable.
Torque: 5 N.m (51 kgf.cm, 44 in.lbf)
35. INSTALL PARKING BRAKE CABLE ASSY NO.3
a. Install the front floor brace LH.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
b. Install the parking brake cable.
Torque: 5 N.m (51 kgf.cm 44 in.lbf)
36. INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
37. INSTALL FUEL TANK PROTECTOR NO.1
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
38. INSTALL FUEL TANK PROTECTOR NO.2
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
39. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
40. INSTALL EXHAUST PIPE ASSY CENTER
41. INSTALL REAR FLOOR SERVICE HOLE COVER
42. INSTALL REAR SEAT ASSY RH
43. INSTALL REAR SEAT ASSY LH
44. INSPECT FUEL LEAK
45. CHECK EXHAUST LEAKAGE
Removal & Installation and Disassembly & Reassembly
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE REAR SEAT ASSY RH
3. REMOVE REAR SEAT ASSY LH
4. REMOVE REAR FLOOR SERVICE HOLE COVER
5. REMOVE FUEL PUMP TUBE SUB-ASSY
6. REMOVE FUEL TANK VENT TUBE SET PLATE
7. REMOVE FUEL SUCTION W/PUMP & GAGE
8. DRAIN FUEL
9. REMOVE EXHAUST PIPE ASSY CENTER
10. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
11. REMOVE FUEL TANK PROTECTOR NO.1
12. REMOVE FUEL TANK PROTECTOR NO.2
13. REMOVE FUEL TANK PROTECTOR LOWER CENTER
14. SEPARATE PARKING BRAKE CABLE ASSY NO.2
a. Remove the parking brake cable.
b. Remove the front floor brace RH
15. SEPARATE PARKING BRAKE CABLE ASSY NO.3
a. Remove the parking brake cable.
b. Remove the front floor brace LH
16. SEPARATE FUEL TANK TO FILLER PIPE HOSE
17. SEPARATE BREATHER TUBE FUEL HOSE
18. SEPARATE FUEL HOSE SUB-ASSY NO.3
19. SEPARATE FUEL CUT OFF W/TUBE VALVE ASSY
20. SEPARATE FUEL TANK VENT HOSE
21. REMOVE FUEL TANK ASSY
a. Remove the 4 bolts and fuel tank.
22. REMOVE FUEL SENDER GAGE ASSY
a. Remove the 6 screws and fuel sender gage.
23. REMOVE FUEL TANK BREATHER TUBE SUB-ASSY
a. Remove the 4 screws, nut and fuel tank breather tube.
24. REMOVE FUEL CUT OFF VALVE ASSY
a. Remove the 4 screws, retainer and fuel cut off valve.
25. REMOVE FUEL CUT OFF VALVE ASSY NO.2
a. Remove the 4 screws, retainer and fuel cut off valve No.2.
26. REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY
a. Remove the 6 screws and fuel tank over fill check valve.
27. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY
a. Install a new gasket and the fuel tank over fill check valve.
28. INSTALL FUEL CUT OFF VALVE ASSY NO.2
a. Insert the fuel cut off valve No.2 to the fuel tank.
b. Install the retainer with 4 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
29. INSTALL FUEL CUT OFF VALVE ASSY
a. Insert the fuel cut off valve to the fuel tank.
b. Install the retainer with the 4 screws.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
30. INSTALL FUEL TANK BREATHER TUBE SUB-ASSY
a. Install a new gasket and fuel tank breather tube.
Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf)
31. INSTALL FUEL SENDER GAGE ASSY
a. Install a new gasket and the fuel sender gauge.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)
32. INSTALL FUEL TANK CUSHION NO.1
a. Install the new fuel tank cushion as shown in the illustration.
33. INSTALL FUEL TANK ASSY
a. Install the fuel tank with 4 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
34. INSTALL PARKING BRAKE CABLE ASSY NO.2
a. Install the front floor brace RH.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
b. Install the parking brake cable.
Torque: 5 N.m (51 kgf.cm, 44 in.lbf)
35. INSTALL PARKING BRAKE CABLE ASSY NO.3
a. Install the front floor brace LH.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
b. Install the parking brake cable.
Torque: 5 N.m (51 kgf.cm 44 in.lbf)
36. INSTALL FUEL TANK PROTECTOR LOWER CENTER
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
37. INSTALL FUEL TANK PROTECTOR NO.1
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
38. INSTALL FUEL TANK PROTECTOR NO.2
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
39. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
40. INSTALL EXHAUST PIPE ASSY CENTER
41. INSTALL REAR FLOOR SERVICE HOLE COVER
42. INSTALL REAR SEAT ASSY RH
43. INSTALL REAR SEAT ASSY LH
44. INSPECT FUEL LEAK
45. CHECK EXHAUST LEAKAGE
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.