Fuel Tank Removal

Disconnect the cable from the negative (-) battery terminal.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

Remove the front driver side scuff plate.

1. Using a screwdriver, detach the 7 claws.
   

   HINT:

   Tape the screwdriver tip before use.

2. Using a clip remover, detach the 3 clips and remove the scuff plate.
   

Fold back the floor carpet and disconnect the joining connector, as shown in the illustration.

HINT:

This connector has the lines of the fuel pump and rear speed sensor.

Connect the cable to the negative (-) battery terminal.

Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.

HINT:

DTC C0210/33 and DTC C0215/34 (rear speed sensor circuit) and DTC P0171/25 (system too lean) may be set.

Crank the engine again, and then check that the engine does not start.

Loosen the fuel tank cap, and then discharge the pressure in the fuel tank completely.

Connect the fuel pump connector.

Install the front driver side scuff plate.

Clear the DTCs (Toyota Fortuner RM000000ZPW007X.html).

Remove the 4 nuts and fuel tank protector.

Remove the 2 tube clamps from the fuel tube.

Pinch and pull the fuel tank main tube connector to disconnect the connector from the pipe. Then pinch and pull the fuel tank return tube connector to disconnect the connector from the pipe.

NOTICE:

1. Remove any dirt and foreign objects from the fuel tube connector before performing this work.
   
2. Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector contains the O-rings that seal the pipe.
   
3. Perform this work by hand. Do not use any tools.
   
4. Do not forcibly bend, twist or turn the nylon tube.
   
5. Keep the plug free from foreign objects.
   
6. Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube.
   
7. If the fuel tube connector and pipe are stuck, push and pull to release them.
   

Disconnect the vent line hose from the fuel pipe.

Disconnect the fuel tank breather hose from the fuel tank filler pipe.

Detach the fuel tank breather hose from the 2 clamps.

Disconnect the fuel tank to filler pipe hose from the fuel tank filler pipe.

Remove the bolt, nut and filler pipe.

Place a transmission jack under the fuel tank.

Remove the 3 bolts, 3 clips, 3 pins and 3 fuel tank bands.

Slightly lower the transmission jack.

NOTICE:

Be careful not to cut the wiring.

Fold back approximately half of each cushion so that the wire harness can be removed in the step below.

Detach the wire harness from the 4 clamps shown in the illustration.

HINT:

Detach the claw of the clamps labeled A in the illustration to detach the wire harness.

Disconnect the fuel pump and sender gauge connector.

Using needle-nose pliers, remove the 5 clips and 2 nuts shown in the illustration and then remove the No. 1 fuel tank protector.

Remove the 4 fuel tank cushions from the fuel tank.

Remove the No. 1 fuel evaporation tube.

Remove the 2 tube joint clips and pull out the 2 fuel tank tubes.

NOTICE:

1. 
   
2. Remove any dirt and foreign matter on the fuel tube joint before performing this work.
   
3. Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
   
4. Perform this work by hand. Do not use any tools.
   
5. Do not forcibly bend, twist or turn the nylon tube.
   
6. Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tubes.
   

Remove the fuel tank return tube and fuel tank main tube from the fuel tank.

Set SST on the fuel pump gauge retainer.

SST

09808-14030

HINT:

1. Engage the claws of SST securely with the fuel pump gauge retainer holes to secure SST.
   
2. Install SST while pressing the claws of SST against the fuel pump gauge retainer (towards the center of SST).
   

Using SST, loosen the retainer.

SST

09808-14030

HINT:

Fit the tips of SST onto the ribs of the retainer.

NOTICE:

1. When the retainer is loosened, be careful as the fuel pump will spring upward from the force of the spring.
   
2. Clean the fuel suction tube before this operation.
   

Remove the fuel pump gauge retainer.

Remove the fuel suction with pump and gauge tube from the fuel tank.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge.

Remove the gasket from the fuel tank.

Remove the fuel tank breather hose from the fuel tank.

Remove the fuel tank to filler pipe hose from the fuel tank.