Fuel Tank Removal

Remove the No. 3 fuel tube clamp from the fuel tube.

Disconnect the fuel main tube and fuel return tube (HILUX_TGN26 RM000000YL401PX.html).

Disconnect the vent line hose.

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

Disconnect the breather hose from the fuel tank filler pipe.

Remove the bolt and filler pipe.

Place a engine lifter under the fuel tank.

Remove the 2 bolts, 2 clips, 2 pins and 2 No. 1 fuel tank bands.

Slightly lower the engine lifter.

NOTICE:

Be careful not to cut the wiring.

Remove the clip. Then fold back approximately half of each cushion rubber so that the wire harness can be removed in the next step.

Detach the wire harness from the 6 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 connector.

Using needle-nose pliers, remove the 4 clips and nut as shown in the illustration, and then remove the No. 1 fuel tank heat insulator.

Remove the clip and No. 1 fuel tank cushions.

Remove the No. 2 fuel tank cushion.

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

NOTICE:

1. Remove any dirt and foreign matter on the fuel tube joint before performing this work.
   
2. 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.
   
3. Perform this work by hand. Do not use any tools.
   
4. Do not forcibly bend, twist or turn the nylon tube.
   
5. 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.

Temporarily install SST (plate and 4 claws) to the fuel pump gauge retainer.

SST

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HINT:

1. Be sure to use 4 SST (claws) as shown in the illustration.
   
2. Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.
   

While pressing SST (claws) against the fuel pump gauge retainer ribs securely, install the 4 bolts.

HINT:

Install SST while pressing SST (claws) against the fuel pump gauge retainer (towards the center of SST).

Install SST (handle).

Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to loosen the fuel pump gauge retainer.

SST

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NOTICE:

1. When the retainer is loosened, be careful as the fuel pump will spring upward from the force of the spring.
   
2. Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
   
3. Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
   
4. Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.
   
5. Do not spin SST too fast or use an impact wrench as this may result in damage to components.
   
6. If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.
   

HINT:

The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.

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.

Detach the 2 claws and remove the protector.

Remove the fuel tank breather hose from the fuel tank.

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