Genuine Toyota Prius Fuel Tank

Toyota Prius Fuel Tank Parts Questions & Answers

• Tank Assy, Fuel
  77001-47080
  Q: What are the precautions and considerations for dealing with the fuel tank in Toyota Prius covered?

  A: The fuel tank installed in the vehicles covered is not repairable; if it becomes damaged, it must be replaced. Cleaning the fuel tank (due to fuel contamination) should be performed by a professional with the proper training to carry out this critical and potentially dangerous work. 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. Be especially careful inside a garage where a gas-type appliance is located. 2004 and later fuel tanks are equipped with rubber bladders that serve to reduce the amount of vapor in the system. Caution: Do not let anyone attempt to repair these tanks. If the tank is damaged, it must be replaced.
• Tank Assy, Fuel
  77001-47071
  Q: How to remove and install a fuel tank?

  A: Remove the fuel filler cap to relieve fuel tank pressure. Relieve the fuel system pressure. Disconnect the cable from the negative terminal of the auxiliary 12-volt battery. Be sure to perform the initialization procedure when reconnecting it. Siphon or pump the fuel into an approved container using a siphoning kit or hand-operated pump (available at most auto parts stores). Raise the vehicle and support it securely on jackstands. Remove the floor brace that is under the exhaust pipe. Disconnect the oxygen sensor (on some models, it will be necessary to remove the center instrument panel cover for access to the connector). Remove the front exhaust pipe. Remove the rear seat cushion. Remove the fuel system access cover in the floor. Disconnect the wiring as you lift it. Disconnect all lines that interfere with fuel tank removal. Note: Be sure to plug the hoses to prevent leakage and contamination of the fuel system. Support the fuel tank with a floor jack. Place a sturdy plank between the jack head and the fuel tank to protect the tank. Loosen the clamp and disconnect the fuel fill pipe from the tank inlet pipe. Remove the bolts from the fuel tank retaining straps and set the straps aside. Lower the tank and disconnect the fuel inlet pipe. Remove the tank from the vehicle. Installation is the reverse of removal.