Toyota 77001-06082
Fuel Tank

The process of fuel tank assembly replacement starting in July 2003 requires you to first perform fuel system pressure discharge followed by back seat cushion assembly and the rear floor service hole cover removal. You should disconnect the fuel pump tube sub-assembly before you remove the fuel tank vent tube set plate to separate the fuel suction tube assembly with pump and gauge. The procedure begins with draining fuel before removing the rear floor panel brace and center exhaust pipe assembly through the removal of 2 bolts and 4 nuts then extracting the exhaust pipe and its accompanying 2 gaskets. Unplug the set bolts and nuts along with the parking brake cable assembly for numbers 2 and 3. Begin by disconnecting the fuel pump tube and then remove the 4 bolts of the lower center fuel tank protector and finally separate the fuel tank assembly while pinching the retainers tab to unlock the lock claws before pulling down without using tools or bending the nylon tube. The procedure starts by setting up a transmission jack below the fuel tank followed by removing the 2 set bolts from the fuel tank bands and disconnecting the fuel tank to filler pipe hose and the fuel tank vent hose from the charcoal canister through connector push and locking pin release. The service starts by taking out the fuel tank and afterward removing its 2 pins and 2 fuel tank bands then finishing with the 4 clip nut removal. Begin the repair procedure by removing both the fuel tank vent hose and the combined parts consisting of fuel pump tube sub-assembly and fuel main tube support. The technician should install 7 new fuel tank cushions after reinstalling the fuel main tube support with 5.4 N.m (55 kgf.cm, 48 in.lbf) torque while also reinstalling the fuel pump tube sub-assembly and fuel tank vent hose. Reposition the fuel tank assembly by tightening the 4 clip nuts and the 2 fuel tank bands with 2 pins while connecting the fuel tank vent hose along with the fuel tank inlet pipe featuring the fuel filler pipe clamp. Finally, torque the set bolts of the fuel tank bands to 39 N.m (400 kgf.cm, 29 ft.lbf). First establish a proper connection for the fuel tube No. 1 by pressing its end until it activates the click mechanism and verify it contains no foreign matter or damage then proceed with the fuel pump tube connection by pressing its connector to secure the lock position. Add the lower center fuel tank protector with 5.4 N.m (55 kgf.cm, 48 in.lbf) torque and then fasten parking brake cables No. 3 and No. 2 at 5.4 N.m (55 kgf.cm, 48 in.lbf). The center exhaust pipe assembly should be reinstalled using two new gaskets and two bolts and four new nuts tightened at 56 N.m (571 kgf.cm, 41 ft.lbf). The end of the installation process includes attaching the fuel suction tube assembly with pump and gauge as well as the fuel tank vent tube set plate followed by connecting the fuel pump tube sub-assembly then checking for leaks before reinstalling the rear floor service hole cover and rear seat cushion assembly and the rear floor panel brace.

The replacement of the fuel tank initiated in July 2003 requires system pressure discharge followed by rear seat cushion removal alongside the rear floor service hole cover. Start by disassembling the fuel pump tube sub-assembly and then remove the fuel tank vent tube set plate followed by taking out the fuel suction tube assembly with pump and gauge. First drain off the fuel while you remove the rear floor panel brace and the center exhaust pipe assembly through the process of taking out two bolts, four nuts, an exhaust pipe and two gaskets. The set bolts and nuts from parking brake cable assembly No.2 and No.3 need removing for disconnect. Use a tool to pinch the tab of the retainer and remove the lock claws before taking out the nylon tube from the fuel tank assembly after disconnecting the fuel pump tube and taking out 4 bolts from the fuel tank protector lower center. To remove the fuel tank you must set up a transmission jack underneath while you disconnect all of its components starting with two fuel tank bands set bolts then remove the fuel tank to filler pipe hose and the fuel tank vent hose from the charcoal canister after pushing its connector deeply into its locking pin. To start services on the fuel tank begin by removing it and next remove the 2 pins along with 2 fuel tank bands which are followed by 4 clip nuts. The procedure requires removal of the fuel tank vent hose along with the fuel pump tube sub-assembly and fuel main tube support through bolt extraction. At first remove 7 new fuel tank cushions from the fuel tank after which install the fuel main tube support using 5.4 N.m (55 kgf.cm, 48 in.lbf) torque. Begin by installing 4 clip nuts to the fuel tank assembly followed by attaching the 2 fuel tank bands alongside their 2 pins to their proper positions then connect the fuel tank vent hose to its fitting along with inserting the fuel tank inlet pipe into the fuel filler pipe clamp before tightening the 2 set bolts of the fuel tank bands to a torque of 39 N.m (400 kgf.cm, 29 ft.lbf). Join fuel tube No.1 with a click motion without damaging anything, while connecting the fuel pump tube set by locking the connectors into place. The installation requires the 5.4 N.m (55 kgf.cm, 48 in.lbf) torque application to secure both No.3 and No.2 parking brake cable assemblies and the lower center fuel tank protector. Along with these elements, the center exhaust pipe requires two new gaskets, two bolts and four new nuts which should achieve 56 N.m (571 kgf.cm, 41 ft.lbf) torque. Reinstall the rear floor service hole cover followed by rear seat cushion assembly then finish with the rear floor panel brace after executing the installation sequence of the fuel suction tube assembly with pump and gauge and the fuel tank vent tube set plate and connecting the fuel pump tube sub-assembly and checking for fuel and exhaust gas leaks before adding fuel.