Toyota 77001-0C040
Fuel Tank

A service or repair of the fuel tank requires that you discharge system pressure while also removing the spare tire then disconnecting the fuel pump connector. The first step is to remove the fuel tank protector through the removal of two bolts and two nuts. After disconnecting the fuel main tube and return tube you must remove the fuel tank vent hose by inserting the connector deeply into the charcoal canister until the locking tab is released and then pinch portion A before removing the connector. The procedure requires the removal of both the inlet hose and breather hose through a plain clamp bolt release and a fuel inlet hose unattachment from the fuel filler pipe and breather tube. A transmission jack should be positioned under the fuel tank before removal of the two bolts and subsequent disconnection of the two fuel tank bands from the fuel tank can allow jack operation to remove the fuel tank. Follow this procedure to install the fuel tank assembly: set up the transmission jack beneath it, operate the jack to mount the fuel tank and then secure the tank by tightening the 2 fuel tank bands around the assembly and installing its 2 bolts with a final torque of 62 N.m (632 kgf.cm, 45 ft.lbf). Put the fuel inlet hose onto the filler pipe and attach the clamp afterward before connecting the breather tube. Attach the fuel tank vent hose to the charcoal canister before uniting the fuel main tube with the return tube. Put on the 2 fuel tank protector bolts together with the 2 nuts before reconnecting the fuel pump connector while thoroughly examining for signs of fuel leakage. Complete the process by reinstalling the spare tire.

Loosen the hose clamp bolt to disconnect the fuel inlet hose from the fuel filler pipe and disconnect the breather tube.