Question about 1992 Toyota 4Runner

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How do I release the gas tank from the intake pipe in order to drop the tank to replace the fuel pump?

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  • easley_marsh Nov 17, 2009

    I have the tank completely disconnected, but I can't get it disconnected from the intake pipe - the place where I put fuel into the tank at the gas station! Where is the release or bolts or connection that separates the intake pipe from the actual gas tank??

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The filler neck is just a rubber hose, remove the clamp and twist the hose back and forth until it breaks free from the metal tank nipple it is on, there is also a special tool for going up under the hose to break the bond between the rubber hose and the metal nipple, most auto part stores like NAPA have these, these hoses can be very difficult to release as they get "VULCANIZED" to the gas tank nipple. blow is a picture of a hose release tool, it is formerly called a Radiator hose release tool.

how do I release the - d2c5831.jpg

Posted on Nov 17, 2009

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  • Toyota Master
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Removal & Installation 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. Raise the vehicle and support it with jackstands.
  3. 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.
  4. Disconnect the plug from the pump and sending unit. Remove the gravel shield from the tank.
  5. Disconnect the fuel lines. Plug all the lines to prevent fuel from leaking.
  6. Disconnect the filler neck and vent line.
  7. Remove the fuel tank protector.
  8. 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.
  9. Remove the fuel pump assembly.

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. Install the fuel tank. Tighten the tank bolts.
  3. Connect the lines and hoses. Make certain the hoses are not crimped or pinched. Make sure the clamps are correctly seated.
  4. Connect the negative battery cable.
how do I release the - 32ed3cc.gif
Exploded view of the fuel tank components-1989-95 4Runner

Posted on Nov 17, 2009

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Posted on Jan 02, 2017

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  2. Properly relieve the fuel system pressure.
  3. Drain and remove the fuel tank from the vehicle
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  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Disconnect the negative battery cable.
  4. Drain the fuel tank into an approved container.
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  5. Raise the vehicle.

    1edb6c2.jpg
    Fig. Showing the fuel tank assembly and related components
  6. Disconnect the fuel supply pipe (5) quick-connect fitting.
  7. Disconnect the evaporative emission (EVAP) purge pipe (6) quick connect fitting at the EVAP canister.
  8. Loosen the fuel tank filler pipe hose clamp.
  9. Disconnect the fuel tank filler from the fuel tank.
  10. Disconnect the vapor recirculation pipe from the filler tube.
  11. Remove the fuel tank shield.
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  14. Disconnect the fuel sender and the fuel tank pressure (FTP) sensor electrical connectors at the body pass through.
  15. Remove the fuel tank from the vehicle.
  16. Remove the fuel sender assembly (3).

    f523c95.jpg
    Fig. Identifying the fuel sender assembly
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  19. Disconnect the fuel supply pipe quick-connect fitting (4) at the fuel sender assembly.
  20. Disconnect the evaporative emission (EVAP) pipe quick-connect fittings (5, 6) at the fuel sender assembly.
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Dear cdkkks,

Replacing a fuel pump in modern cars requires some preliminary electrical, fuel test analysis work. I have noted some professionals indicating you need to run car until gas lines, tank is empty; more than likely, if your fuel pump is defective, you cannot start the car, car is unoperative; you will attempt to start car, starter will turn the engine over rapidly without starting, let's assume you are in this condition.

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(A) Park your Crown Vic, perferably in a garage, concrete floor and make sure there is enough room around the back of the vehicle for you to work and move tools around.

(B) Raise the back of your car using a floor jack and support it safely on wheel/jack stands; remember, the driver side rear wheel must be removed in order to remove the fuel tank filler pipe, place your wheel stand (supplement with 2 by material for proper height on frame,slightly forward of rear wheel); safety is the key issue here and I cannot overly emphasize this issue, heavy wheel stands should be supporting the right rear wheel and frame, slightly forward of rear wheel, driver side).

(C) Disconnect the fuel tank filler pipe and the fuel pump connector located above the cross member underneath the vehicle, you must remove the (3) screws on the topside (fuel tank fiiler pipe) and approximately (4) screws on the bottom side, and the (1) screw adapter plate where the fuel tank filler pipe is inserted into the gas tank, top of wheel opening, underneath the vehicle. After these connections are removed, push the fuel tank filler pipe further into the fuel tank, allowing you additional room to lower the filler pipe from it's current position, downward; once you have sufficient clearance, twist, turn left, slightly back and forth movements and carefully pull outward, removing the filler pipe from gas tank. Do not damage the rubber groment in gas tank as you remove the filler pipe. As a note, when you reinstall the filler pipe, insert small amount of vasoline on filler pipe end that is inserted into the gas tank to facilitate the installation process.

(D) Support the fuel tank with a jack and remove the nuts from the holding strap using a wrench or ratchet and socket. Move the strap away and slightly lower the fuel tank in order to disconnect the vapor tube from the tee connector on the right and the vapor line from the canister tube. Discard the fuel tank mounting studs and replace with new fuel tank mounting studs on the reinstallation process.

(E) Unplug the pressure transducer electrical connector located on the top rear corner of the fuel tank.

(F) Clean area around the mounting fuel pump mounting flange. Remove/disconnect the fuel lines attached to fuel pump mounting flange then remove the fuel pump mounting flange mounting bolts in a crisscross pattern.

(G) Lift the fuel pump assembly off the tank. Replace the new fuel pump in the assembly and install the assembly in the tank. Install the flange screws and torque to approximately 89 inch lbs using a crisscross pattern. If no torque wrench is available, tighten to a snug fit and stop.

(H) Afterwards, raise the fuel tank enough to attach fuel lines and vapor lines indicated above, item D. After connecting all lines, raise tank with floor jack to its original position "carefully" and utilize the new mounting bolts, securing straps in their original position and torque bolts to approximatlely 25-30 lbs torque.

(I) Install the fuel tank filler pipe per the aforementiond process reversed.

(J) Review your connections and then carefully lower the vehicle, use a gas container, input 4-5 gallows of gas and start the engine and check for leaks.

Wishing you the very best,

drprice

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2 Answers

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  1. Relieve the fuel system pressure.
  2. Disconnect the negative battery cable.
  3. Remove the rear exhaust pipe and muffler assembly.
  4. On All Wheel Drive (AWD) vehicles, remove the rear differential assembly and the rear crossmember. You do not have AWD so this step is not for you
  5. Remove the fuel filler cap and drain the fuel into a suitable container.
  6. Remove the fuel filler pipe protector.
  7. Raise and support the vehicle safely on jackstands.
  8. Remove the fuel filler, air vent and delivery hoses.
  9. On AWD vehicles, disconnect the air breather hoses and evaporation hose from the pipes.
  10. Support the fuel tank with a floor jack or equivalent lifting device.
  11. Loosen the attaching bolts and lower the fuel tank slightly.
  12. Disconnect the fuel pump harness

Feb 18, 2009 | 1992 Subaru Legacy

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