Toyota 77001-08060
Fuel Tank

Service and repair work on the fuel tank requires the operator to first eliminate fuel system pressure. Users need to remove the charcoal canister protector and fuel tank filler hose cover by unbolting the 3 fasteners. The fuel tank vent hose connector should be disconnected by opening its locking tab and pulling out the connector while pinching portion A. The next step requires disconnecting the fuel tank main tube through pinching action on the connector to draw it outside while ensuring the O-ring of the quick connector stays free from contaminants. Before working with the nylon tube protect its connector using a vinyl or plastic bag while avoiding any tool usage or bending or twisting movement. The pipe and connector require gentle pulling and pushing motions to become unstuck. To disconnect the hose between fuel tank to filler pipe remove the clamp bolt first then pull off the other hose. At the same time remove the fuel tube by disconnecting its clamp. Begin by removing two wire harness clamps while setting up a transmission jack under the fuel tank then disassembling the 6 bolts on three fuel tank bands. The operation of the transmission jack requires you to first loosen the 4 wire harness claw fasteners and delete the fuel pump connector and vapor pressure sensor connector before taking off the fuel tank and its 3 fuel tank bands from the vehicle. Remove the fuel tank main tube sub assembly and fuel suction tube assembly with pump and gauge by using Special Service Tool: 09808-14020 (09808-01410, 09808-01420, 09808-01430). Drain the fuel from the tank and unfurl the fuel tank to filler pipe hose by unfastening the hose clamp bolt. You can detach the fuel tank vent hose by disconnecting its 3 clamps while triggering the locking tab with a hose clip to free the connector and remove it. The installation process requires connecting the fuel tank vent hose while installing a new fuel tank to filler pipe hose and reinstalling the fuel suction tube assembly with pump and gauge through the use of Special Service Tool: 09808-14020 (09808-01410, 09808-01420, 09808-01430). First set up the fuel tank on the transmission jack and then assemble the fuel tank main tube sub assembly. Working with the transmission jack requires you to secure the 4 wire harness clamps then join the fuel pump connector and vapor pressure sensor connector before setting the fuel tank and its 3 bands to the vehicle. Install the fuel tube by inserting the connector until it clicks while you tighten the 6 set bolts of the 3 fuel tank bands to 33 N.m (336 kgf.cm, 24 ft.lbf). Then install the 2 wire harness clamps. Examine both connected parts for integrity before starting the procedure while also testing the connection security. Complete the fuel tank hose connector process by pressing the filler pipe hose and the fuel tank main tube so each connection produces a click sound. The procedure concludes by connecting the fuel tank vent hose followed by fuel addition and a leak check before installing the filler hose cover to 5.0 N.m (51 kgf.cm, 44 in.lbf) with reattachment of the charcoal canister protector.