Fuel Sub Tank Removal

Engine Hybrid System. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
2Tr-Fbe Fuel. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE AUXILIARY FUEL TANK ASSEMBLY

  4. REMOVE SOLENOID VALVE ASSEMBLY

  5. REMOVE FUEL TANK FILLER PIPE SUPPORT

  6. REMOVE FUEL TANK CAP ASSEMBLY

  7. REMOVE FUEL TANK CAP COVER

  8. DRAIN FUEL

  9. REMOVE NO. 2 FUEL TUBE SUB-ASSEMBLY

  10. REMOVE FUEL PUMP

  11. REMOVE CHECK VALVE GASKET

  12. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY

  13. REMOVE FUEL TANK FILLER PIPE

  14. REMOVE BREATHER TUBE FUEL HOSE

Fuel Sub Tank -- Removal



1. PRECAUTION
NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (HILUX_TGN26 RM000004QR1006X.html).


2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR300CX.html).


3. REMOVE AUXILIARY FUEL TANK ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Disconnect the connector and No. 3 fuel hose.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Disconnect the fuel sender gauge connector.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Disconnect the No. 4 fuel hose.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Disconnect the fuel pump connector.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Disconnect the No. 2 fuel tank filler tube.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the 2 bolts and auxiliary fuel tank assembly.

    NOTICE:
    1. Do not drop the auxiliary fuel tank.
    2. Do not damage the piping or wiring.


4. REMOVE SOLENOID VALVE ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Disconnect the hose.

  1. Remove the bolt and solenoid valve assembly.



5. REMOVE FUEL TANK FILLER PIPE SUPPORT


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the No. 1 fuel tank filler pipe support and No. 2 fuel tank filler pipe support.



6. REMOVE FUEL TANK CAP ASSEMBLY


7. REMOVE FUEL TANK CAP COVER


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the tie wrap and fuel tank cap cover.



8. DRAIN FUEL


9. REMOVE NO. 2 FUEL TUBE SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Disconnect the fuel pump connector.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Detach the claw, then disconnect the No. 2 fuel tube sub-assembly.

    HINT:
    1. A filter is built in the No. 2 fuel tube.
    2. If the No. 2 fuel tube is clogged, replace it with a new one.


10. REMOVE FUEL PUMP


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Pull out the fuel pump.



11. REMOVE CHECK VALVE GASKET


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the check valve gasket.



12. REMOVE FUEL SUCTION PLATE SUB-ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the fuel pump gauge retainer.

    NOTICE:
    Perform this work by hand. Do not use any tools.

  1. Remove the fuel suction plate sub-assembly.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the fuel suction tube set gasket.



13. REMOVE FUEL TANK FILLER PIPE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Loosen the hose clamp, then remove the fuel tank filler pipe.



14. REMOVE BREATHER TUBE FUEL HOSE


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Loosen the hose clamp, then remove the breather tube fuel hose from the fuel tank sub-assembly.