OEM Toyota Fuel Tank

Toyota Fuel Tank Parts Questions & Experts Answers

• Tank Assembly, Fuel
  77001-3D510
  Q: How to service and repair the fuel tank assembly on Toyota 4Runner?

  A: 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.
• Fuel Tank
  77001-06082
  Q: How to replace the fuel tank on Toyota Camry?

  A: 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.
• Fuel Tank
  77001-04201
  Q: How to install the fuel tank on Toyota Tacoma?

  A: The process begins with attaching the No. 1 fuel tank protector to its places using four clips. Apply the fuel tank to the filler pipe hose before you tighten the pipe clamp bolt. We should apply a new gasket on the fuel tank before setting the fuel pump assembly inside while making sure the gauge sender arm stays undamaged. Air the spline of the fuel suction tube assembly into keyway position of the fuel tank before attaching a new retainer while positioning its mark on the fuel tank rib. The retainer 740 degrees should be turned clockwise using Service Tool 09808-14020 09808-01410 up to a maximum of 780 degrees to reach range A. After this, install the main tube and return tube with their 2 joint clips by checking that nearby parts have no scratches or foreign materials present before securely fastening the clips. Set the mission jack under the fuel tank assembly while connecting the fuel tank vent hose by inserting its connector into the pipe until it clicks and fitting the fuel pump connector with the filler pipe hose. The installation of fuel pump cover, two fuel tank bands requires two pins, two clips and two bolts while torque settings reach 62 Nm (632 kgf-cm, 46 ft-lbf). The breather tube should be attached securely until it clicks before installing the pipe checker followed by bolt clamp tightening. Install the fuel pipe clamp after connecting both the fuel tank main tube and return tube which fit into position securely. A fuel mixture should be added before connecting a cable to the negative terminal with a torque setting of 3.9 Nm (40 kgf-cm, 35 in-lbf) while inspecting for fuel leakages.