How to replace the fuel tank on Toyota Highlander?

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Accepted Answer

Before working on the fuel tank you need to drain the fuel system pressure and afterward take away the deck board sub-assembly and rear seat track bracket cover outer along with both left and right rear seat assemblies and rear door scuff plate on the left-hand side and the rear floor service hole cover followed by the fuel suction tube assembly and pump and gauge unit. The propeller with center bearing shaft assembly (4WD type) must be removed together with exhaust pipe assembly center and front floor heat insulator No.3 and exhaust pipe support bracket No.4 (4WD type) requires removing 2 bolts to proceed. The sequential steps involve removing the first fuel tube protector by taking off its 2 clips and unscrewing the claw before moving to the first fuel tank protector followed by its assembly No.1 through disassembly of 4 nuts with 3 clips ( 1) and 6 nuts. To disconnect the fuel pump tube you can remove the lock claws by pinching the retainer projection until they unlock and pull the tube out while maintaining a clean state of the connector. Unfasten the fuel tank to filler pipe hose by loosening its hose clamp bolt before disassembling the fuel tank vent hose and breather tube No.3. Set the transmission jack below the fuel tank before removing the 4 bolts and 2 fuel tank bands along with the 2 nuts to operate the jack for fuel tank removal. Extract the combination of fuel pump tube sub-assembly with the fuel tank to filler pipe hose alongside the fuel tank vent hose while taking out the tank suction tube support and fuel tank side plate and fuel tank cushion set. Set the new fuel tank cushion set alongside the side plate before torquing to 30 N.m (306 kgf.cm, 22 ft.lbf); thereafter insert the tank suction tube support along with the fuel tank vent hose and fuel tank to filler pipe hose. Set the transmission jack under the fuel tank assembly then torque two fuel tank bands with 4 bolts to 39 N.m and two nuts to 20 N.m. Neatly connect the components which include fuel tank wire connector and fuel tank to filler pipe hose together with fuel tank breather tube No. 3 and fuel tank vent hose while verifying all attachments are tight. Begin by clicking the quick connector into place and afterward install sub-assembly No.1 and its attached 6 nuts with torque to 5.5 N.m (56 kgf.cm, 49 in.lbf) in addition to the 3 new retainers before installing parts No.1 and No.1. Reposition and torque the exhaust pipe support bracket No.4 (4WD type) to 22 N.m (224 kgf.cm, 16 ft.lbf) along with front floor heat insulator No.3 and exhaust pipe assembly center. After filling the tank with fuel install the pump gauge assembly onto the suction tube before checking for any gas or fuel leaks. The last step involves reinstalling the rear floor service hole cover, followed by both rear door scuff plate left-hand side pieces, rear seat assemblies (both left and right), and rear seat track bracket cover outer. Deck board sub-assembly installation comes next, then the propeller with center bearing shaft assembly (4WD type) then a full tightening of the propeller assembly. Transfer oil (4WD type) addition follows before an inspection of transfer oil (4WD type).

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