Toyota 4Runner 2001-06

Removal & Installation

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Fig. Exploded view of the fuel tank and related components-2003-05 Models



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Fig. View of the fuel tank and related components-2001-02 Models

  1. Properly relieve the fuel system pressure.
  2.  
  3. Raise the vehicle and support it with safety stands.
  4.  
  5. If equipped with a drain plug, remove the drain plug and drain any remaining fuel into a suitable container. If the tank has no drain plug, a siphon pump will be required to remove the fuel. Remember that it is possible to have several gallons in the tank; be prepared with sufficient containers. It is best to run the tank as low on fuel as possible before removing it, but keep in mind that -Empty- on the gauge may still leave 2 or 3 gallons in the tank.
  6.  
  7. Disconnect the plug from the fuel pump and sending unit assembly. On 2003-05 modes, there is an access cover in the floor, under the mat to access the connectors. Remove the gravel shield, if equipped, from the tank.
  8.  
  9. Disconnect the fuel lines. Plug all the lines to prevent fuel from leaking.
  10.  
  11. Disconnect the filler neck and vent line.
  12.  
  13. Remove the fuel tank protector.
  14.  
  15. Remove the bolts holding the tank to the vehicle and carefully lower the tank. It is recommended that a jack with a broad piece of lumber be placed to support the tank.
    CAUTION
    Even though the tank has been drained, it still contains highly explosive fuel vapor. Immediately place the tank outside; NEVER store it in the house or garage. Unless the tank is to be immediately reinstalled, use a hose to fill the tank with water as full as possible. This will flush remaining fuel and vapor from the tank and also carry off any dirt which has accumulated.

  16.  

To install:

  1. Make certain the fuel tank is completely dry if it has been flushed. Install the pump assembly, if removed.
  2.  
  3. Install the fuel tank. Tighten the tank bolts.
  4.  
  5. Connect the lines and hoses. Make certain the hoses are not crimped or pinched. Make sure the clamps are correctly seated.
  6.  
  7. Connect the negative battery cable.
  8.  

 
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