Relieve pressure in the fuel system.
Remove the fuel filler cap from the fuel tank, which will equalize the pressure in the fuel tank with atmospheric pressure.
Turn off the ignition and disconnect the ground wire from the battery.
If there is fuel in the fuel tank, pump it out. Pump out the fuel using a special pump.
Raise the car on a lift.
Remove the rear and center sections of the exhaust system.
On all-wheel drive vehicles, remove the driveshaft.
(The original version is published on the website: www.TOYOTAMAN.ru)
Figure 5.16. Connection points of fuel lines and fuel vapor return pipe to the fuel tank
Disconnect the fuel lines, fuel vapor return tube and filler neck from the fuel tank (figure 5.16). Close the fuel lines with plastic plugs to prevent fuel leakage and contamination of the fuel system.
Support the fuel tank with a jack and a wooden block.
Figure 5.17. Location of fuel tank support strap mounting bolts
Figure 5.18. Fuel tank of vehicles manufactured before 2001: 1 – gasket; 2 – fuel pump/fuel level sensor unit; 3 – tube fastening clamp; 4 – fuel tank cap; 5 – gasket; 6 – main fuel tank pipe; 7 – filling control valve; 8 – fuel level sensor; 9 – protective cover of the filling control valve; 10 – thick fuel pipe; 11 – air removal tube; 12 – protective plate; 13 – tube; 14 – filler neck; 15 – filler neck; 16 – filler cap; 17 – retaining ring; 18 – clamps; 19 – fuel inlet hose; 20 – protective plate; 21 – fuel tank; 22 – fuel tank support band; 23 – protective plate; 24 – protective plates
Remove the fuel tank support strap mounting bolts (figure 5.17, 5.18).
Lower the fuel tank enough to allow the electrical connector to be disconnected from the fuel pump/fuel level sensor assembly.
Remove the fuel tank from under the vehicle.
Warning! Even an empty fuel tank contains fuel vapors that are explosive, so use caution.
Any repair to the fuel tank or filler neck should be performed by a professional who is experienced in performing critical and potentially hazardous work. Even after cleaning and flushing the fuel tank, it still contains explosive fuel vapors.
Later production vehicles are equipped with fuel tanks made of plastic, which cannot be repaired.
The removed fuel tank must be located away from open flames, sparking devices, open fire-hazardous lighting devices and smoking areas.
Install the fuel tank in the reverse order of removal.
Figure 5.19. Air filter on models before 2001: 1 – accelerator cable; 2 – power steering hydraulic system reservoir; 3 – air filter element; 4 – expansion tank; 5 – slip control relay; 6 – electrical connector for the engine air temperature sensor; 7 – Positive crankcase ventilation (PCV) hose; 8 – high-voltage wires; 9 – air hose; 10 – air filter cover; 11 – air filter housing; 12 – relay block No. 2; 13 – throttle control cable; 14 – gasket; 15 – fuel supply pipe; 16 – gasket
Figure 5.20. Air filter on models since 2001: 1 – ignition coil; 2 – ignition coil electrical connector; 3 – air filter housing; 4 – air filter element; 5 – air filter bracket
Remove and install the air filter housing as follows: (figures 5.19 and 5.20):
Release the spring clips and remove the air cleaner cover and element.
On pre-2001 models, disconnect the electrical connector from the slip control relay located on the side of the air cleaner cover.
On 2001 and later models, disconnect the air intake hose from the air cleaner cover.
Figure 5.21. Location of air filter housing mounting screws
Remove 3 screws and remove the air filter housing (figure 5.21).
Install the air filter housing in the reverse order of removal.
Install the air filter housing in the reverse order of removal.