OEM 2005 Toyota Tacoma Fuel Tank

2005 Toyota Tacoma Parts Questions & Experts Answers

• Q: How to service and repair the fuel tank on 2005 Toyota Tacoma?

  A: Service and repair work on the fuel tank requires two steps - draining fuel system pressure followed by negative battery terminal cable disconnection. The service requires removal of fuel tank protector sub-assembly No.1 with W/ OFF ROAD PACKAGE since it has 4 nuts holding it in place. Users should disconnect the fuel tank main tube along with the fuel tank return tube through fuel pipe clamp detachment followed by retainer pinch until fuel tube connectors emerge from the pipes while verifying both parts have no dirt or scratches. To separate the fuel tank assembly disconnect the fuel breather tube while carefully removing the fuel tank from the filler pipe hose and by ensuring protective measures for the wire harness and hose. Use your fingers to pinch the retainer of both the fuel pump connector and fuel tank vent hose to take them out of their positions in the charcoal canister. Remove the fuel tank assembly and discharge the main tube across the return tube through the removal of the joint clips. The fuel suction w/ pump & gauge tube assembly requires the use of Special Service tool 09808-14020 (09808-01410, 09808-01420, 09808-01430) to remove its retainer before pulling the fuel pump assembly out of the fuel tank but nurses the sender gauge arm from bending during extraction and removal of the gasket. Remove the fuel tank to filler pipe hose through unscrewing its clamp bolt and drain the fuel tank contents. Secure the fuel tank protector No.1 to its position with four clips while installing the fuel tank to filler pipe hose and tightening the pipe clamp bolt. First install a new gasket onto the fuel tank followed by placement of the fuel pump assembly into the tank and afterward a spline from the fuel suction tube assembly must slot into the keyway of the fuel tank. Apply special service tool number 09808-14020 to facilitate the installation of a new retainer while rotating it counterclockwise between 740 and 780 degrees until the mark on the retainer matches the fuel tank rib. Fit the fuel tank main tube and return tube to the 2 joint clips after checking for scratches or foreign objects. Place the mission jack under the fuel tank assembly and connect the tank vent hose while ensuring its proper connection. The filler pipe hose links to the fuel pump connector and the fuel tank before installing the two fuel tank bands with attached pins and clips. Place two bolts and torque them to 62 N.m (632 kgf.cm, 46 ft.lbf). The fuel tank breather tube must be connected and its clamp bolt must be tightened before securing the fuel tank main tube with the return tube and verifying proper connection points. The final step includes fuel tank protector sub-assembly No.1 (W/ OFF ROAD PACKAGE) installation with 4 nuts subjected to 20 N.m (204 kgf.cm, 15 ft.lbf) torques. Add fuel and connect the cable to the negative battery terminal, and perform fuel leakage inspection.