Toyota 77001-69035 Tank Assy, Fuel

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All repairs to the fuel tank or filler neck should be carried out by a professional with experience in this critical and potentially dangerous work. It is important to note that even after cleaning and flushing the fuel system, explosive fumes can still remain and ignite during tank repair. Additionally, 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 emitted from the tank. This caution is particularly important in garages with natural gas-type appliances, as the pilot light could potentially cause an explosion.

The procedure for removing a fuel tank is as follows: First, relieve the pressure in the tank by removing the fuel tank filler cap. Then, detach the cable from the negative terminal of the battery. If the tank still has fuel, drain it using a siphoning kit or by removing the drain plug. Next, raise the vehicle and secure it on jackstands. Remove the screws from the top of the fuel filler neck and disconnect it from the body of the vehicle. Disconnect the fuel lines and vapor return line, making sure to label them if needed. Loosen the hose clamp and detach the fuel filler neck from the tank. If there is still fuel in the tank, siphon it out from the fuel feed port. Remove the protective shield if present. Support the fuel tank with a floor jack and disconnect the retaining straps. Lower the tank to disconnect the wires and ground strap from the fuel pump/fuel gauge sending unit. Finally, remove the tank from the vehicle. If there is an auxiliary fuel tank, the removal process is similar. Installation is the reverse of removal.