Last Modified: 08-21-2023 6.11:8.1.0 Doc ID: RM100000001B4O0
Model Year Start: 2019 Model: Avalon Prod Date Range: [04/2018 - 08/2021]
Title: 2GR-FKS (FUEL): FUEL TANK: REMOVAL; 2019 - 2021 MY Avalon [04/2018 - 08/2021]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fuel tank assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link
*: When performing learning using the Techstream.

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; PARK ASSIST / MONITORING: INTELLIGENT CLEARANCE SONAR SYSTEM (for Gasoline Model): CALIBRATION

Battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane Departure Alert System (w/ Steering Control)

2019 - 2021 MY Avalon [04/2018 - 08/2021]; PRE-COLLISION: PRE-COLLISION SYSTEM (for Gasoline Model): INITIALIZATION

Pre-collision System

Intelligent Clearance Sonar System*

Lighting System (for Gasoline Model with Cornering Light)

Memorize steering angle neutral point

Parking Assist Monitor System

2019 - 2022 MY Avalon [04/2018 -        ]; PARK ASSIST / MONITORING: PARKING ASSIST MONITOR SYSTEM (for Gasoline Model): INITIALIZATION

Panoramic View Monitor System

2019 - 2022 MY Avalon [04/2018 -        ]; PARK ASSIST / MONITORING: PANORAMIC VIEW MONITOR SYSTEM (for Gasoline Model): INITIALIZATION

Gas leak from exhaust system is repaired

Inspection after repair
  • Poor idle, etc.
  • Engine start function, etc.

2019 MY Avalon [04/2018 - 08/2019]; 2GR-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION 2020 - 2022 MY Avalon [08/2019 -        ]; 2GR-FKS (ENGINE CONTROL): SFI SYSTEM: INITIALIZATION

CAUTION:

  • Never perform work on fuel system components near any possible ignition sources.
  • Vaporized fuel could ignite, resulting in a serious accident.
  • Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
  • The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

PROCEDURE

1. REMOVE FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Click here 2019 - 2021 MY Avalon [04/2018 - 08/2021]; 2GR-FKS (FUEL): FUEL PUMP: REMOVAL

2. DRAIN FUEL

3. REMOVE CENTER EXHAUST PIPE ASSEMBLY

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (INTAKE / EXHAUST): EXHAUST PIPE: REMOVAL

4. REMOVE NO. 2 FLOOR UNDER COVER

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; REAR SUSPENSION: REAR STABILIZER BAR (for 2WD): REMOVAL+

5. REMOVE NO. 1 FLOOR UNDER COVER

Click here 2019 - 2022 MY Avalon Avalon HV [04/2018 -        ]; REAR SUSPENSION: REAR STABILIZER BAR (for 2WD): REMOVAL+

6. REMOVE NO. 1 FUEL TANK PROTECTOR

(a) Using needle nose pliers, remove the 4 clips and No. 1 fuel tank protector from the fuel tank assembly.

*a

Needle Nose Pliers

7. DISCONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Disconnect the fuel tank main tube sub-assembly from the fuel pipe.

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (FUEL): FUEL SYSTEM: PRECAUTION

8. DISCONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY

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

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (FUEL): FUEL SYSTEM: PRECAUTION

9. DISCONNECT FUEL TANK TO FILLER PIPE HOSE

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

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (FUEL): FUEL SYSTEM: PRECAUTION

10. REMOVE FUEL TANK ASSEMBLY

CAUTION:

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

(a) w/ Fuel Outlet Valve Assembly:

(1) Disconnect the fuel cut off valve with tube assembly from the fuel outlet valve assembly.

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (FUEL): FUEL SYSTEM: PRECAUTION

(b) w/o Fuel Outlet Valve Assembly:

(1) Disconnect the fuel cut off valve with tube assembly from the canister (charcoal canister assembly).

Click here 2019 - 2022 MY Avalon [04/2018 -        ]; 2GR-FKS (FUEL): FUEL SYSTEM: PRECAUTION

(c) Support the fuel tank assembly using an engine lifter.

HINT:

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

(d) Remove the 4 bolts, No. 1 fuel tank band sub-assembly LH and No. 1 fuel tank band sub-assembly RH.

(e) Lower the engine lifter to remove the fuel tank assembly.

NOTICE:

  • Be careful not to drop the fuel tank assembly.
  • When removing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.

11. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Disengage the clamp to remove the fuel tank main tube sub-assembly from the fuel tank assembly.

12. REMOVE NO. 6 FUEL TANK CUSHION

(a) Remove the No. 6 fuel tank cushion from the fuel tank assembly.

13. REMOVE NO. 1 FUEL TANK CUSHION

(a) Remove the 2 No. 1 fuel tank cushions from the fuel tank assembly.