Toyota 77001-3D510
Tank Assembly, Fuel

The first step to work on the fuel tank assembly requires preventing gasoline from leaking. The center floor hole cover removal starts with holding the rear No. 1 seat assemblies on both sides while removing the tear-off floor mat and unscrewing the 3 screws in addition to disconnecting the 2 connectors. Service work on the fuel tank assembly starts by detaching the fuel tank-to-filler-pipe hose from the fuel filler pipe before draining all fuel content. The mission jack needs to be placed under the fuel tank protector to support it before removing the six securing bolts. Pinch the tabs holding the retainer claws to release the lock and pull out the tubes starting from the main fuel tank line followed by the return line while checking that no dirt can be found at the quick connector locations. Disable the fuel tank breather tube by pinching and pulling out its retainer tab while separating the fuel tank vent hose by deep insertion of its connector followed by pinching a specific area before removal. A mission jack will provide support for the fuel tank assembly to release it from its position through the removal of both bolts and fuel tank bands. To proceed with removal, detach the main and return tubes while removing the joint clips before carefully pulling them out. The process requires complete cleaning of the quick connector areas. Loosen the retainer of the fuel suction tube assembly with Special Service Tool: 09808-14020 (09808-01410, 09808-01420, 09808-01430) before pulling out the assembly along with its gasket. Proceed with reinstalling the fuel tank breather tube through a tab pinch motion followed by tube removal and separation of the fuel tank-to-filler pipe hose. Connect the new filler hose while inserting the breather tube connector into the pipe until it clicks without any damage or foreign objects. Using the Special Service Tool secure the retainer around the fuel suction tube assembly which now holds a new gasket as its proper placement in the keyway enables installation. Install the 3 new fuel tank cushions while you use joint clips to connect the fuel tank main tube with the return tube. A mission jack should assist the fuel tank reinstallation followed by tightening 2 bolts through the tank assembly and connecting 2 fuel tank bands to a torque of 40 N.m (408 kgf.cm, 30 ft.lbf). Securely install the fuel tank tube components by making them lock into position. The fuel tank protector can now be installed with 6 bolts tightened at 20 N.m (204 kgf.cm, 15 ft.lbf) whereby the fuel tank can be connected to the filler pipe hose after checking for any leaking condition.

Before performing any service or repair work on the fuel tank assembly the operator should protect against gasoline spillage. The center floor hole cover removal begins when the rear No. 1 seat assemblies are held on both sides while removing the tear-off floor mat followed by unscrewing 3 screws and disconnecting 2 connectors. You should remove the fuel filler pipe's fuel-tank-to-filler-pipe hose to drain the fuel into a container. The mission jack must support the fuel tank protector before you unfasten the 6 bolts to detach it. Users should disconnect the fuel tank main tube and return tube by pinching retainer tabs to free lock claws and pulling out the tubes while checking for any dirt contamination near the quick connector. Remove the fuel tank breather tube through a tab retention pinch followed by disconnecting the fuel tank vent hose by pushing its connector deep inside and pinching a designated area before pulling it out. Thread the assembly through the mission jack to remove it followed by unbolted 2 bolts, 2 fuel tank bands and disconnecting the fuel tank. According to the maintenance manual remove the fuel tank cushion by disregarding two joint clips and extracting the tubes while maintaining a clean area around the quick connector. SST 09808-14020 allows removal of the fuel suction tube assembly when performed by loosening the retainer while pulling out the assembly before removing the gasket. Step one to detach the fuel tank breather tube sub-assembly consists of pushing the retainer tab forward to remove the assembly. The gas tank requires a new filler hose after removing its inlet hose. The installation of the breather tube sub-assembly requires pushing the connector to the pipe until it clicks then installing the retainer while inspecting the area for damage or foreign debris. The fuel suction tube assembly must be installed with a new gasket while verifying that the fuel sender gauge arm remains straight before tightening the retainer with SST 09808-14020. Users must connect the fuel tank main tube and return tube with a joint clip after inspecting for scratches and foreign objects. Afterward they must install 3 new fuel tank cushions. The tank should be suspended by a mission jack before securing it with 2 fuel tank bands and bolts which need to be torqued to 40 N.m. Next, establish secure connections between the breather tube sub-assembly with the main and return tubes. Install the six fuel tank protector bolts that require 20 N.m torque before connecting the fuel tank to the filler pipe hose and verifying tank leakage.

Use Special Service Tool: 09808-14020 to loosen the retainer, then remove the retainer and pull out the fuel suction tube assembly.

Set a mission jack to the fuel tank and remove the 2 bolts, 2 fuel tank bands, and the fuel tank.