Toyota 77001-42190
Fuel Tank

The first step to remove the fuel tank demands pressure discharge and negative battery terminal cable disconnection followed by minimum ninety-second waiting time to stop the Air Bag and seat belt pretensioner activation. Begin by removing the fuel tank cap followed by taking out the nut, bolt and 3 clips to access the front floor cover and next extracting the No.1 floor under cover by disassembly of its 2 nuts and single clip. The No. 2 parking brake cable assembly needs 2 bolts removed to disconnect it while the fuel tank main tube sub-assembly requires pinching and pulling its connector manually to disconnect it without tools while checking for any foreign material which may damage O-rings or create leaking conditions. Customers should remove the EVAP hose as well as fill pipe hose and breather hose from the fuel tank and examine for foreign elements and limit nylon tube bending force. Begin by disconnecting the fuel tank filler pipe through the removal of 3 bolts together with the filler pipe protector and then the remaining 2 bolts for the filler pipe. Lower the transmission jack under the fuel tank then take out the 6 bolts and 3 fuel tank bands while maintaining caution to avoid cutting any wires. Detach the wire harness from each cushion rubber halfway to access the fuel pump and sender gauge connectors before disconnecting them. Ensure the connectors stay free of contamination. To install the fuel tank position it on the transmission jack then lift it and fold back the cushion rubbers before joining the fuel pump and sender gauge connectors while ensuring all wiring remains intact. Flood the wire harness into the clamps before tightening the fuel tank bands with 6 bolts set to produce 40 N.m (408 kgf.cm and 30 ft.lbf). The filler pipe requires installation through 2 bolts which should be torqued to 23.5 N.m (240 kgf.cm, 17 ft.lbf) before installment of the filler pipe protector completed with 3 bolts. The filler pipe hose and breather hose need to be connected to the fuel tank while inspecting the components for damage as well as foreign matter. Push the main tube sub-assembly connector until it clicks securely then join the EVAP hose after. Place the No. 1 floor under cover using two nuts and a clip followed by installation of the front floor cover with three clips and a bolt and a nut while putting the No. 2 parking brake cable assembly together through two bolts. After installing the fuel tank cap you should reconnect the cable to the negative battery terminal while performing an inspection for fuel leaks.

Begin by removing the fuel tank main tube sub-assembly.