Toyota Tundra Service Manual: Removal

REMOVAL

PROCEDURE

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 (See page ).

2. DISCHARGE FUEL SYSTEM PRESSURE

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

4. REMOVE FUEL TANK CAP

5. REMOVE NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (for Rough Road Area Specification Vehicles)

(a) Remove the 2 bolts, 2 nuts and No. 1 fuel tank protector sub-assembly.

6. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Detach the lock claw by lifting up the cover as shown in the illustration.

(b) Pinch and pull the fuel tank main tube connector to disconnect the fuel tank main tube sub-assembly from the pipe.

NOTICE:

• Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
• Do not use any tools to separate the pipe and connector.
• Do not forcefully bend or twist the nylon tube.
• Check for foreign matter on the pipe seal surface. Clean if necessary.
• Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
• If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

7. DISCONNECT FUEL TANK RETURN TUBE

(a) Detach the lock claw by lifting up the cover as shown in the illustration.

(b) Pinch and pull the fuel tank return tube connector to disconnect the fuel tank return tube from the pipe.

NOTICE:

• Check for foreign matter in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.
• Do not use any tools to separate the pipe and connector.
• Do not forcefully bend or twist the nylon tube.
• Check for foreign matter on the pipe seal surface. Clean if necessary.
• Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
• If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

8. DISCONNECT VENT LINE HOSE

(a) Pull up the retainer and disconnect the vent line hose. Text in Illustration *a Up NOTICE: Do not use any tools in this procedure. Check for any dirt and foreign matter contamination in the valve and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the valve and connector.

9. DISCONNECT WIRE HARNESS

(a) Detach the harness clamp from the fuel tank assembly.

10. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Detach the lock claw by lifting up the cover as shown in the illustration. Text in Illustration *1 Pipe *2 Retainer *3 Connector *4 O-Ring *5 Nylon Tube *a Lifting Up

(b) Disconnect the fuel tank breather tube from the inlet fuel tank pipe sub-assembly.

(c) Disconnect the fuel tank to filler pipe hose from the inlet fuel tank pipe sub-assembly.

(d) Detach the filler pipe hose and fuel tank breather tube from the No. 1 breather tube clamp.

11. DISCONNECT OUTLET NO. 1 CHARCOAL CANISTER HOSE

(a) Disconnect the outlet No. 1 charcoal canister hose from the inlet fuel tank pipe sub-assembly.

(b) Detach the hose from the No. 1 breather tube support.

12. REMOVE FUEL TANK ASSEMBLY

(a) Set a transmission jack underneath the fuel tank assembly.

(b) Remove the 2 bolts, 2 clips, 2 pins, No. 1 fuel tank band sub-assembly and No. 2 fuel tank band sub-assembly.

(c) Slowly lower the transmission jack slightly.

NOTICE:

Be careful not to cut the wiring.

(d) w/ Cover: Detach the 3 claws to remove the No. 2 fuel tank protector.

(e) Detach the wire harness clamp from the fuel tank assembly as shown in the illustration.

(f) Disconnect the fuel pump and fuel sender gauge connector and lower the transmission jack.

NOTICE:

• Before this procedure, check the connector for dirt, mud or other contamination.
• Do not use any tools in this procedure.

13. REMOVE INLET FUEL TANK PIPE SUB-ASSEMBLY

(a) Remove the 2 nuts and inlet fuel tank pipe sub-assembly.

14. REMOVE NO. 1 FUEL TANK HEAT INSULATOR

(a) Remove the nut from the No. 1 fuel tank heat insulator.

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

15. REMOVE FUEL TANK TO FILLER PIPE HOSE

(a) Remove the fuel tank to filler pipe hose from the fuel tank assembly.

16. REMOVE FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

17. REMOVE NO. 1 FUEL TANK PROTECTOR (w/ Cover)

HINT:

Only perform this procedure when replacement of the No. 1 fuel tank protector is necessary.

(a) Detach the 4 clamps to remove the No. 1 fuel tank protector.