Fuel Tank Assembly: Replacement

For rear floor panel brace (see COMPONENTS )

1. Remove the 2 bolts, 4 nuts, exhaust pipe and 2 gaskets.

1. Remove the set bolt and the set nut of the parking brake cable.
   Fig 1: Removing Set Bolt & Set Nut Of Parking Brake Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the set bolt and the set nut of the parking brake cable.
   Fig 2: Removing Set Bolt & Set Nut Of Parking Brake Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts and fuel tank protector.
   Fig 3: Removing Bolts Of Fuel Tank Protector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the fuel pump tube.
   1. Pinch the tab of the retainer to remove the lock claws and pull down it as shown.
   2. Pull out the fuel tank main tube.
      Fig 4: Disconnecting Fuel Pump Tube

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Before this operation, check the connector for dirt, mud or other contamination.
   • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
   • Do not use any tools in this operation.
   • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
   • When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
     Fig 5: Identifying Fuel Tube Connector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the fuel tube No. 1.
   1. Pinch the tube connector and then pull out the fuel tube No. 1.
      Fig 6: Disconnecting Fuel Tube No. 1.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Before this operation, check the connector for dirt, mud or other contamination.
   • Be careful of mud. The connector's O-ring, which seals the pipe and connector, becomes contaminated easily.
   • Do not use any tools in this operation.
   • Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
   • When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe.
     Fig 7: Identifying Nylon Tube & Tube Connector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set up a transmission jack underneath the fuel tank.
4. Remove the 2 set bolts of the fuel tank bands.
5. Remove the hose clamp and disconnect the fuel tank to filler pipe hose.
6. Disconnect the fuel tank vent hose from the charcoal canister.
   1. Push the connector deep into the charcoal canister to release the locking pin.
   2. Pinch portion A.
   3. Pull out the connector.
7. Remove the fuel tank.
   Fig 8: Disconnecting Fuel Tank Vent Hose From Charcoal Canister

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the 2 pins and 2 fuel tank bands as shown in the illustration.
   Fig 9: Removing Pins & Fuel Tank Bands

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the 4 clip nuts.
   Fig 10: Removing Clip Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Push the connector deep into the charcoal canister to release the locking pin.
2. Pinch portion A.
3. Pull out the connector.
   Fig 11: Removing Fuel Tank Vent Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the fuel pump tube from the fuel main tube support.
   Fig 12: Removing Fuel Pump Tube From Fuel Main Tube Support

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and tube support.
   Fig 13: Removing Bolt & Tube Support

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 7 new fuel tank cushions to the fuel tank.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

1. Install the 4 clip nuts.
2. Install the 2 fuel tank bands with the 2 pins.
3. Connect the fuel tank vent hose.
4. Connect the fuel tank inlet pipe with the fuel filler pipe clamp.
5. Tighten the set 2 bolts of the fuel tank bands.

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

6. Connect the fuel tube No. 1.
   1. Push the fuel tube connector into the pipe until fuel tube connector makes "click" sound.
   NOTE:

   • Check if there is any damage or foreign objects on the connected part.
   • After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart.
     Fig 15: Pushing Fuel Tube Connector Into Pipe

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the fuel pump tube.
   1. Push in the fuel tube connector to the pipe until, and push up retainer to the claws lock.
   NOTE:

   • Check if there is any damage or foreign objects on the connected part.
   • After connecting, check if the fuel tube connector and the pipe are securely connected by trying to pull them apart
     Fig 16: Connecting Fuel Pump Tube

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

1. Install 2 new gaskets and the exhaust pipe with the 2 bolts and 4 new nuts.

   Torque: 56 N.m (571 kgf.cm, 41 ft.lbf) 

For floor panel brace (see COMPONENTS )