Fuel Tank (For Hatchback) Removal

Engine Hybrid System. Yaris. Ncp93, 131
1Nz-Fe Fuel. Yaris. Ncp93, 131

  1. PRECAUTION

  2. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

  3. DRAIN FUEL

  4. REMOVE REAR CONSOLE BOX ASSEMBLY

  5. REMOVE FRONT FLOOR CENTER BRACE

  6. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  7. REMOVE EXHAUST PIPE GASKET

  8. REMOVE NO. 2 EXHAUST PIPE GASKET

  9. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR

  10. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY

  11. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

  12. DISCONNECT FUEL TANK VENT HOSE

  13. REMOVE FUEL TANK ASSEMBLY

  14. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

  15. REMOVE FUEL TANK VENT HOSE

  16. REMOVE FUEL TANK FILLER PIPE PROTECTOR

  17. REMOVE BREATHER TUBE CLAMP

Fuel Tank (For Hatchback) -- Removal



1. PRECAUTION


    Yaris. Ncp93, 131.1Nz-Fe Fuel.Fuel System (For Sedan).Fuel Tank (For Hatchback)  Removal
  1. When removing and storing the fuel tank assembly, arrange the inlet hose as shown in the illustration, and secure the fuel tank assembly using a cord or similar.

    Text in Illustration
    *1
    Cord
    NOTICE:
    Depending on the arrangement of the inlet hose during storage, the inlet hose and rear suspension may interfere and cause fuel leakage.


2. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
(YARIS_NCP93 RM000004NLO00FX.html)


3. DRAIN FUEL


4. REMOVE REAR CONSOLE BOX ASSEMBLY
(YARIS_NCP93 RM000003726005X.html)


5. REMOVE FRONT FLOOR CENTER BRACE


Yaris. Ncp93, 131
  1. Remove the 2 bolts and the front floor center brace from the body.



6. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    Yaris. Ncp93, 131
  1. Peel back the floor carpet.



    Yaris. Ncp93, 131
  1. Disconnect the heated oxygen sensor connector.

  1. Remove the oxygen sensor wire grommet and pass the connector through the hole to the outside of the vehicle.



    Yaris. Ncp93, 131
  1. Remove the 2 bolts and 2 compression springs from the exhaust manifold.



    Yaris. Ncp93, 131
  1. Remove the 2 bolts and 2 compression springs from the tail exhaust pipe assembly.

  1. Remove the 3 exhaust pipe supports and the front exhaust pipe assembly.



7. REMOVE EXHAUST PIPE GASKET
  1. Remove the exhaust pipe gasket from the exhaust manifold.



8. REMOVE NO. 2 EXHAUST PIPE GASKET
  1. Remove the No. 2 exhaust pipe gasket from the front exhaust pipe assembly.



9. REMOVE FRONT NO. 4 FLOOR HEAT INSULATOR


    Yaris. Ncp93, 131
  1. Remove the 2 nuts and the front No. 4 floor heat insulator.



10. REMOVE FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    Yaris. Ncp93, 131
  1. Pinch and remove the clip as shown in the illustration.

  1. Remove the bolt and the fuel tank cover vent case sub-assembly.



11. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
NOTICE:
Before disconnecting the fuel tube connector, check for dirt or other foreign matter on the fuel tube connector and the pipe, and clean them if necessary.


    Yaris. Ncp93, 131.1Nz-Fe Fuel.Fuel System (For Sedan).Fuel Tank (For Hatchback)  Removal
  1. Disengage the fuel tube connector cover.

    Text in Illustration
    *1
    Retainer
    *2
    O-ring
    *3
    Fuel Tube Connector
  1. Pinch the retainer by hand from both sides, and pull out the fuel tube connector from the pipe.

    NOTICE:
    1. If the fuel tube connector and pipe are stuck together, push in and pull out the fuel tube connector while squeezing the pipe to release the connection, and then disconnect the fuel tube connector.
    2. Clean away any dirt or foreign matter from the fuel tube connector before performing the operation.
    3. The fuel tube connector and pipe are sealed by O-rings, so be careful to prevent damage to and foreign matter sticking to the contact surfaces.
    4. Do not use any tools.
    5. After disconnecting the fuel tube connector, check that there is no foreign matter on the seal surface of the pipe.
    6. After disconnecting the fuel tube, protect the contact surfaces by covering them with a plastic bag.
    7. Do not bend or twist the tubes.


12. DISCONNECT FUEL TANK VENT HOSE
NOTICE:
Before disconnecting the fuel tank vent hose sub-assembly, check for dirt or other foreign matter on the fuel tank vent hose sub-assembly and the charcoal canister assembly, and clean them if necessary.


    Yaris. Ncp93, 131.1Nz-Fe Fuel.Fuel System (For Sedan).Fuel Tank (For Hatchback)  Removal
  1. Release the retainer as shown in the illustration and disconnect the fuel tank vent hose sub-assembly.

    Text in Illustration
    *1
    Retainer
    Yaris. Ncp93, 131
    Push
    Yaris. Ncp93, 131
    Pull


13. REMOVE FUEL TANK ASSEMBLY


Yaris. Ncp93, 131
  1. Remove the bolt, disengage the claw and separate the fuel tank filler pipe assembly.

  1. Using an engine lifter, support the fuel tank assembly.



    Yaris. Ncp93, 131
  1. Remove the bolt and separate the parking brake cable.



    Yaris. Ncp93, 131
  1. Remove the 4 bolts and fuel tank assembly.

    NOTICE:
    Make sure that the fuel tank does not fall.


14. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY


    Yaris. Ncp93, 131
  1. Remove the fuel tank main tube from the fuel tank assembly.



15. REMOVE FUEL TANK VENT HOSE


    Yaris. Ncp93, 131
  1. Remove the fuel tank vent hose sub-assembly from the fuel tank assembly.



16. REMOVE FUEL TANK FILLER PIPE PROTECTOR


Yaris. Ncp93, 131
  1. Remove the clip from the fuel tank filler pipe protector.

  1. Disengage the 2 claws and remove the No. 2 fuel tube support protector.

  1. Disengage the 2 claws and remove the fuel tank filler pipe protector.



17. REMOVE BREATHER TUBE CLAMP


    Yaris. Ncp93, 131
  1. Disengage the claw and clamp as shown in the illustration, and remove the breather tube clamp.