Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1 through 8

The gas tanks on all Toyota trucks are mounted basically the same. Each one has a shield, straps, inlet pipe and so on. The procedure below is basic, and should help ease your way to the tank removal.

  1. Remove the negative battery cable.
  2.  
  3. Raise the vehicle and support it with jackstands.
  4.  
  5. Remove the drain plug and drain any remaining fuel into a suitable container. 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 Empty on the gauge may still leave 2 or 3 gallons in the tank.
  6.  
  7. Disconnect the plug from the pump and sending unit. Remove the gravel shield 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.
  16.  
  17. Remove the fuel pump assembly.
  18.  


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.

To install:
  1. Make certain the fuel tank is completely dry if it has been flushed. Install the pump assembly.
  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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Fig. Fig. 1: Exploded view of the fuel tank components-1989-95 Pick-Ups



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Fig. Fig. 2: Exploded view of the fuel tank components-Tacoma



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Fig. Fig. 3: Exploded view of the fuel tank components-1989-95 4Runner