Toyota 77001-04180 Tank Assy, Fuel

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The fuel tanks installed in vehicles are not repairable and must be replaced if damaged. Cleaning the fuel tank, often necessary due to fuel contamination, is a critical and potentially dangerous task that should be performed by a professional with the proper training. Even after cleaning and flushing, explosive fumes may remain inside the fuel tank. If the fuel tank is removed from the vehicle, it should not be placed in an area where sparks or open flames could ignite the fumes coming out of the tank. Extra caution is needed inside a garage where a gas-type appliance is located.

Relieve the fuel system pressure and remove the fuel tank cap. Disconnect the cable from the negative terminal of the battery. Raise the vehicle and place it securely on jackstands. Remove the fuel tank rock guard, if equipped. Loosen the lower hose clamp for the fuel tank filler neck hose and disconnect the filler neck hose from the fuel tank. If you're unable to disconnect the filler neck hose from the tank at this time, you can disconnect it after you lower the tank slightly. Also disconnect the quick-connect fitting for the fuel tank breather line. Unless the fuel level in the tank is very low, siphon any fuel from the tank through the filler neck pipe into an approved container. Disconnect the fuel supply and fuel return line quick-connect fittings at the front of the fuel tank. Support the fuel tank. Locate and remove the two fuel tank strap bolts on the left side of the tank, then remove the strap pivot pins on the right side of the tank and remove both fuel tank straps. Carefully lower the tank slightly, remove the fuel pump module cover, disconnect the electrical connector from the fuel pump/fuel gauge sending unit and disconnect the fuel tank vent hose from the EVAP canister. Make sure that there are no other hoses or wiring harnesses still connected, then carefully lower the fuel tank to the floor. Installation is the reverse of removal. Be sure to tighten the fuel tank strap bolts securely.