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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 19 (Fuel System (A25A-FXS) - Service Information (2 Of 2)) >> Fuel Tank >> Removal [11/2023 - ] >> Procedure

Removal [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [11/2023 - ]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2023 - ]

  3. REMOVE BATTERY SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 4

  4. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

  5. REMOVE FRONT FLOOR COVER LH 
    1. Remove the 5 bolts (A), 3 screws (B) and screw (C).
      GTY895351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clips (D), clip (E) and 5 grommets (F) to remove the front floor cover LH.
  6. DISCONNECT FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank evaporation vent tube sub-assembly from the fuel vapor containment valve (close tank with bolt valve assembly).

      Refer to PRECAUTION [11/2023 - ]

      GTY880850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tank main tube sub-assembly from the fuel pipe.
      GTY880851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2023 - ]

  8. DISCONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Disconnect the fuel tank filler pipe sub-assembly from the fuel tank sub-assembly.
      GTY880843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2023 - ]

  9. REMOVE FUEL TANK SUB-ASSEMBLY 
    WARNING:

    The fuel tank sub-assembly is very heavy. Be sure to follow the procedure described in the repair information, or the fuel tank sub-assembly may fall off the engine lifter.

    1. Disconnect the fuel tank breather tube sub-assembly from the fuel tank filler pipe sub-assembly.
      GTY880853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2023 - ]

    2. Disconnect the 2 No. 2 floor wire connectors.
      GTY880852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Support the fuel tank sub-assembly using an engine lifter.
      GTY880844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Using height adjustment attachments and plate lift attachments, keep the fuel tank sub-assembly horizontal.

    4. Remove the 5 bolts, No. 1 fuel tank band sub-assembly and No. 2 fuel tank band sub-assembly.
      GTY935558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Lower the engine lifter to remove the fuel tank sub-assembly.
      NOTE:
      • Be careful not to drop the fuel tank sub-assembly.
      • When removing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the surrounding parts.
  10. REMOVE FUEL TANK PRESSURE SENSOR (VAPOR PRESSURE SENSOR) 

    Refer to PROCEDURE - Step 2

  11. DISCONNECT FUEL TANK WIRE 

    See step  16

  12. DISCONNECT FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY 

    See step  17

  13. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 

    See step  18

  14. REMOVE FUEL PUMP GAUGE RETAINER 

    See step  19

  15. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    See step  20

  16. DRAIN FUEL 
  17. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disengage the 2 clamps to remove the fuel tank main tube sub-assembly from the fuel tank sub-assembly.
      GTY880845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY 
    1. Disengage the clamp and disconnect the fuel cut off valve with tube assembly from the fuel tank evaporation vent tube sub-assembly.
      GTY880841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [11/2023 - ]

    2. Disengage the 2 clamps to remove the fuel tank evaporation vent tube sub-assembly from the fuel tank sub-assembly.
      GTY880842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FUEL TANK WIRE 
    1. Disengage the 4 clamps to remove the fuel tank wire from the fuel tank sub-assembly.
      GTY880840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 3 FUEL TUBE CLAMP 
    1. Disengage the clamp to remove the No. 3 fuel tube clamp from the fuel tank sub-assembly.
      GTY880836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 2 FUEL TUBE CLAMP 
    1. Disengage the 2 clamps to separate the fuel tank breather tube sub-assembly from the fuel tank sub-assembly.
      GTY880837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 No. 2 fuel tube clamps from the fuel tank breather tube sub-assembly.
      GTY880838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE NO. 1 FUEL TANK HEAT INSULATOR 
    1. Remove the 3 clips and No. 1 fuel tank heat insulator from the fuel tank sub-assembly.
      GTY880872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 2 FUEL TANK PROTECTOR 
    1. Disengage the 2 clips and remove the No. 2 fuel tank protector from the fuel tank sub-assembly.
      GTY880873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Disengage the 2 claws and remove the No. 1 fuel tank protector sub-assembly from the fuel tank sub-assembly.
      GTY880874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE NO. 6 FUEL TANK CUSHION 

    HINT: 

    Perform this procedure only when replacement of the No. 6 fuel tank cushion is necessary.

    1. Remove the 5 No. 6 fuel tank cushions from the fuel tank sub-assembly.
      GTY880839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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