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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Fuel System >> Fuel System (2GR-FKS) - Service Information >> Fuel Tank >> Removal [12/2019 - 10/2022] >> Procedure

Removal [12/2019 - 10/2022]: Procedure

  1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022] 

  2. DRAIN FUEL 
  3. REMOVE FRONT FLOOR COVER LH 
    1. Remove the 4 bolts (A) and 6 screws (B).
      GTY849085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clip (C) and 2 grommets (D) to remove the front floor cover LH.
  4. REMOVE NO. 1 FLOOR UNDER COVER 
    1. Remove the 4 bolts (A) and screw (B).
      GTY842917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clip (C), clip (D), clip (E) and 4 grommets (F) to remove the No. 1 floor under cover.
  5. REMOVE REAR SUSPENSION MEMBER SUB-ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022]

  6. DISCONNECT FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY 
    1. Disengage the clamp and disconnect the fuel tank evaporation vent tube sub-assembly from the canister (charcoal canister assembly).

      Refer to PRECAUTION [12/2019 - 10/2022]

      GTY887352Courtesy 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.
      GTY887353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [12/2019 - 10/2022]

  8. 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. for 2WD:
      1. Remove the nut to separate the engine service cover assembly and rear main muffler heat insulator sub-assembly from the vehicle body.
        GTY887355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tank breather tube sub-assembly from the fuel tank filler pipe sub-assembly.
      GTY887356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [12/2019 - 10/2022]

    3. Disconnect the lower fuel tank filler pipe sub-assembly from the fuel tank filler pipe sub-assembly.
      GTY887347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Refer to PRECAUTION [12/2019 - 10/2022]

    4. Support the fuel tank sub-assembly using an engine lifter.
      GTY887348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    5. Remove the 5 bolts, No. 1 fuel tank band sub-assembly and No. 2 fuel tank band sub-assembly.
      GTY887350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. 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.
  9. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Disengage the 3 clamps to remove the fuel tank main tube sub-assembly from the fuel tank sub-assembly.
      GTY887339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY 
    1. Disengage the 4 clamps to remove the fuel tank evaporation vent tube sub-assembly from the fuel tank sub-assembly.
      GTY936998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 FUEL TUBE CLAMP 
    1. Disengage the clamp to remove the No. 1 fuel tube clamp from the fuel tank sub-assembly.
      GTY887341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE NO. 2 FUEL TANK PROTECTOR 
    1. Remove the clip and No. 2 fuel tank protector from the fuel tank sub-assembly.
      GTY887343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 2 FUEL TUBE CLAMP 
    1. Disengage the clamp to separate the fuel tank breather tube sub-assembly from the fuel tank sub-assembly.
      GTY887334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 2 fuel tube clamp from the fuel tank breather tube sub-assembly.
      GTY936997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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 3 No. 6 fuel tank cushions from the fuel tank sub-assembly.
      GTY887337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE NO. 1 FUEL TANK CUSHION 

    HINT: 

    Perform this procedure only when replacement of the No. 1 fuel tank cushion is necessary.

    1. Remove the No. 1 fuel tank cushion from the fuel tank sub-assembly.
      GTY887328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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