Removing a Fuel Tank | Prius 2010, 2011, 2012, 2013, 2014, 2015

Removing a Fuel Tank | Prius 2010, 2011, 2012, 2013, 2014, 2015

There is a better way, involving the hatch door under the driver side backseat and a fuel line with a blue cap that opens and allows you to drain fuel using a battery and some wires connected to the fuel pump connector (shown in 2 other videos:

Overall better video for removing the tank:
   • The best way to remove a Prius fuel tank  

2 min video for expelling fuel from the tank:
   • Expelling Fuel from Prius Tank - quic...  

00:00 The first trick I tried to fix the leak
00:14 Turns out you can't siphon fuel from most modern cars, but definitely not the 3rd generation Prius. In the above videos, I explain and demonstrate expelling fuel
00:34 Raising the vehicle with ramps and a jack and jack stands
00:50 I had to use a broken LED light as a work light - the green bulb busted so it couldn't be white, but it looked neat anyway
01:02 the maintenance man came to my rescue with correct sockets, encouragement, and humor
01:20 tricky hose to get around to access fuel tank strap bolts - don't give up, just use a 10" extension and try different angles, you'll get it
01:35 fuel was dripping on us the whole time, mind you
01:52 pro tip: put the bolts back in the holes they belong in after removing what it holds in place. They aren't all the same and it's hard to remember where they go
02:04: 10mm, 12mm, and 14mm sockets are needed for this task
02:25 Removing the fuel pump connection. This is SO MUCH EASIER FROM UNDER THE BACKSEAT - and much less of a risk of damaging this! I can't believe we just jabbed at it from below.
02:52 removing the fuel line's suction tube - also WAY EASIER FROM UNDER THE BACKSEAT
03:11 Disconnecting the large fuel filler pipe with green cap. This is much easier if you unscrew the plastic shield blocking it (lol, duh) as shown in video listed above
03:47 Disconnecting the breather tube (green clip) - be careful about dirt getting into any of these connections
04:49 Disconnecting the smaller fuel filler pipe (orange clip)
05:03 The tank is dismounted, to our great pleasure and awe
05:20 Looking at the fuel pump connection assembly
05:33 looking at the top of the tank
06:21 opening the fuel pump connection assembly
07:04 transporting it! (and my garbage)
07:37 Removing remaining fuel
08:24 carefully hosing it down (you don't want water in there)

Tools:
Ratchet
10" ratchet extension
Large screwdriver
10mm socket
12mm socket
14mm socket
pick tools
pry tool
gloves
safety goggles
work lights
jack
jack stands
car ramps
12V battery, alligator clips
gas can

Removal Steps:
Drive car up ramps
Remove backseat
Jack up car
(removing Left Rear wheel is helpful)
Unplug power
Remove fuel using vent tube
Access fuel pump through the hatch under the backseat
Disconnect fuel pump connector
Use a battery and alligator clips to pump remaining fuel out
Disconnect suction tube
Unscrew the bolt holding the plastic shield under the large fuel filler pipe (green clip)
Disconnect fuel filler pipes (2. Large one with green clip and small one with orange clip). Squeeze the back of the clips and use pick tools
Disconnect breather tube (green clip)- use something small and strong to squeeze the back part and use pick tools to pull the rest of it out
Remove rear brace - Left side
-Remove the 14mm bolts on the left side before removing the 10mm bolts holding the plastic bc the plastic piece will get in the way and make it difficult to remove the 14mm bolts
Remove rear brace - Right side
-Remove the 10mm bolts holding the plastic to access the 2nd 14mm bolt for the brace
Remove the tank shield using 10mm sockets
Remove the fuel tank straps using 14mm sockets and a 10" ratchet extension
Lower tank out gently

Tips:
Put bolts back in the holes they belong to because otherwise it's hard to remember which bolts go where.
Put all your tools in a bin and drag the bin around with you when you get under the car
Add WD-40 to your bin of tools and use it liberally

Re-installation steps:
Use your whole body to maneuver the tank into place
Replace the tank straps with 14mm socket and 10" extension
Replace the tank shield with 10mm socket
Replace the rear brace - Put the bolts in loosely until they are all in place. Then tighten.
Reconnect the fuel filler pipes using dielectric grease to help
Reconnect the breather tube using dielectric grease
Push the screw up to reinstall the plastic shield that covers the fuel filler pipes
Go up to the hatch and reconnect the fuel pump connection
Reconnect the suction tube
Replace the hatch access cover
Replace the backseat
Lower the car from the jackstands
Replug the power

If any of the parts you came across during this job need replacing or you want more information on them, I created a Google doc for all of that here:
https://docs.google.com/presentation/...

For example -
Fuel tank (part #77001-47110):
https://parts.bouldertoyota.com/oem-p...