Question 1

How to remove and install the fuel tank on Toyota 4Runner?

Accepted Answer

The fuel tank removal process starts with relieving fuel system pressure before operators can remove the rear floor service hole cover by holding the rear No1 seat assemblies LH and RH while removing a tear-off floor mat and unscrewing 3 screws followed by connector disconnection. The first step includes separating the fuel-tank-to-filler-pipe hose from the filler pipe while draining fuel before setting a mission jack to the fuel tank protector to remove six bolts. Remove the lock claws from the retainer by pinching its tabs to extract the two fuel tank tubes while checking for any dirt around quick connectors then covering tubes with vinyl bags. The fuel tank breather tube sub-assembly needs disconnecting by pressing the tab of the retainer and removing the tube while the fuel tank vent hose requires disconnecting by placing the connector deeply inside and pinching portion A before pulling out the connector. Remove the fuel tank assembly while setting a mission jack below the tank and then lose the two bolts followed by the two fuel tank bands followed by the fuel tank. Unlock the 2 tubes joint clips to remove the fuel tank main tube and the return tube and the fuel tank cushion. Use Special Service Tool 09808-14020 (09808-01410, 09808-01420, 09808-01430) to remove the retainer from the fuel suction with pump & gauge tube assembly before pulling out the assembly while taking care to avoid bending the sender gauge arm. Start installation by pinching the tube's retaining tab and pulling out the tube until it reaches completion. Then proceed to take off the fuel tank to filler pipe hose. Install the new fuel tank to filler pipe hose first before pushing the tube connector into the fuel tank breather tube sub-assembly until it clicks and tightening the retainer. First install a new gasket onto the fuel tank before setting the fuel suction tube assembly to the tank and inserting the spline into its keyway. Finish by installing a new retainer while using the Special Service Tool for tightening. The tube joint clip requires connection to the fuel tank main tube after ensuring no scratches or foreign objects remain present as the installation continues with three new fuel tank cushions. A mission jack should be used to install the fuel tank assembly which must be tightened using 2 bolts and 2 fuel tank bands to a torque value of 40 N.m (408 kgf.cm, 30 ft.lbf). There are two steps to complete before finishing this procedure: connect the fuel tank main tube to the return tube then to the fuel tank breather tube by matching the clicking parts. The back floor service hole cover installation process starts with connecting the connector after which the 3 screws must be installed before reattaching the rear floor carpet assembly.

Question 2

How to install the fuel tank on Toyota Tacoma?

Accepted Answer

The installation process for the 2TR-FE fuel tank begins with attaching the No. 1 fuel tank protector through 4 clips. You must attach the fuel tank to the filler pipe hose while securing it with proper pipe clamp bolt tightening. Set the fuel pump assembly into the tank with the arm of the sender gauge free of any bends before installing a fresh gasket on the fuel tank. Insert the spline portion of the fuel suction tube assembly in the keyway of the fuel tank before installing a new retainer which should align its mark with the tank rib while you use tool 09808-01410 to torque the retainer to 740-780 degrees range A. Following the setup of Special Service Tool: 09808-14020 09808-01410 rotate the retainer 740 degrees to 780 degrees clockwise to place the mark inside range A. After that install both fuel tank tubes using the two joint clips while inspecting for any scratches or foreign elements around the attached parts and confirming correct clip positioning. Place the fuel tank assembly on the mission jack while you secure the fuel tank vent hose through connecting its connector with the pipe until it clicks into place then verify all connections are tight. Secure the fuel pump connector followed by attachment of the fuel tank to filler pipe hose which is then covered by the fuel pump cover. Fasten the 2 fuel tank bands to the 2 pins and 2 clips and 2 bolts while torquing them to 62 Nm (632 kgf-cm, 46 ft-lbf). The fuel tank breather tube needs to be attached while its locking mechanism clicks into position then you should install a checker onto the pipe before applying torque to the clamp bolt. Thoroughly connect the main tubes and return tubes of the fuel tank where they lock into position to become secure. Connect the negative battery cable by first adding fuel before installation of the clamp and torquing the cable screw to 3.9 Nm (40 kgf-cm, 35 in-lbf). Finally, check for fuel leaks.

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