Toyota 77001-06112
Tank Assembly, Fuel

Initializing some systems after negative battery cable disconnection is mandatory before commencing the fuel tank removal process that starts by both lowering fuel system pressure and terminating the battery power. The first step involves taking out the rear seat cushion assembly together with the rear floor service hole cover and separating the fuel pump tube sub-assembly. Start by draining the fuel then disconnect the fuel suction tube assembly with pump and gauge along with the fuel tank vent tube set plate. Uninstall the exhaust pipe assembly center followed by disconnection of parking brake cable assemblies No. 2 and No. 3 through the removal of their set bolts and nuts. The low center bolt at the fuel tank protector needs removal followed by disconnecting the fuel pump tube through tab pinching and claw lock release to pull it down while maintaining connector cleanliness. Pull out the fuel tube connector No. 1 after pinching its tube connector while maintaining a clean area around the connector. You must place the transmission jack under the fuel tank and then detach the 2 set bolts which secure the fuel tank bands so you can take off the hose clamp to disconnect the fuel tank filter pipe hose and finally separate the fuel tank vent hose from the charcoal canister through connector deep locking pin engagement and pinching portion A before removing the connector. End the procedure by taking out the fuel tank and both pins and fuel tank bands and their associated 4 clip nuts.

Service and repair of the fuel tank begins with discharging the fuel system pressure before moving on to remove the rear seat cushions for all models followed by the rear floor service hole cover. Begin the fuel tank service by removing the fuel pump tube sub-assembly together with the fuel tank vent tube set plate and fuel pump assembly while you drain the fuel. First remove the floor panel brace rear and the center exhaust pipe assembly by taking out 2 bolts, 4 nuts and the exhaust pipe together with its associated 2 gaskets. The No.2 and No.3 parking brake cable assemblies should be disconnected by removing the set bolts and nuts from each component. Take four bolts out to remove the fuel tank protector lower center before pulling down the fuel pump tube by pinching its tab and removing the lock claws. Check the connector for any contamination during this process. After pinching the tube connector you should pull out the fuel tube No.1 while inspecting each connector for any sign of contamination. A transmission jack goes beneath the fuel tank and operators should remove the 2 watershed bolts securing the fuel tank bands and do a hose disconnect operation on both the fuel tank to filler pipe ( 1) and the fuel tank vent ( 2) from the charcoal canister through locking pin release then A pinching and connector extraction. The fuel tank removal procedure begins by removing 2 pins and 2 fuel tank bands and the 4 clip nuts successively. First disconnect the fuel tank from the fuel filler pipe hose and the fuel tank vent hose from the charcoal canister ( 2) by pushing the connector deep into the canister while using portion A to pinch. Then remove the fuel tank vent hose along with the fuel pump tube sub-assembly and the fuel main tube support. The first step involves installing seven new fuel tank cushions onto the fuel tank before tightening the fuel main tube support to 5.4 N.m (55 kgf.cm, 48 in.lbf). Then install the fuel pump tube sub-assembly and fuel tank vent hose. Install the fuel tank assembly through steps of securing 4 clip nuts and attaching 2 fuel tank bands with 2 pins while connecting the fuel tank vent hose and fuel tank inlet pipe to the fuel filler pipe clamp and tightening the set 2 bolts of the fuel tank bands to 39 N.m (400 kgf.cm, 29 ft.lbf). Connect Fuel Tube No.1 after pushing the connector until it clicks and inspect for any damage or foreign objects. Then connect the fuel pump tube by following the connector with the retainer lock installed. Begin by installing the fuel tank protector lower center with 5.4 N.m (55 kgf.cm, 48 in.lbf) torque after which you should attach the No.3 and No.2 parking brake cable assemblies using a torque of 5.4 N.m (55 kgf.cm, 48 in.lbf). Use 2 new gaskets to assemble the center exhaust pipe together with the exhaust pipe while using 2 bolts and 4 new nuts that need to be tightened to a torque value of 56 N.m (571 kgf.cm, 41 ft.lbf). The last steps include installing the fuel pump assembly while adding fuel and examining leakages then installing the rear floor service hole cover with rear seat cushion assembly for Coupe or without rear seat cushion assembly and installing the floor panel brace rear.

Attach the 2 fuel tank bands using the 2 pins.

Install the fuel pump tube to the fuel main tube support.

Add fuel and then connect the cable to the negative battery terminal.

Reinstall the fuel pump tube sub-assembly and the fuel tank vent hose.

Tighten the 2 set bolts of the fuel tank bands to a torque of 39 N.m (400 kgf.cm, 29 ft.lbf).

Prevent gasoline from spilling out and disconnect the cable from the negative battery terminal.

The fuel pump tube sub-assembly, fuel tank vent tube set plate, and the fuel suction tube assembly with pump and gauge.