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View Full Version : Project Fuel Tank Drop - Step-by-Step How-To



-==L=a=N=c=E==-
12-18-2004, 08:38 AM
Operation Fuel Drop: Remove Tank

Well today started the day i would really get cracking into fixing all the little niggling problems i have had with the car since day 1. And the first and obvious one is the Fuel Tank Leak. So this morning i went about removing the tank. Step by Step.

1) Disconnect battery for atleast 30seconds before working.

2) Locate Service Hole
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/01service%20hole.JPG

3) Remove Service Hole
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/02serviceholeremoved.JPG

4) Remove Fillerpipe Protector
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/03filler%20protector.JPG

5) Fuel Line which need to be disconnected
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/05fuellines.JPG

6) Fuel Inlet - I was going to remove it, but i couldn't get the door opener removed
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/06fuelinlet.JPG

7) Remove bolts from Inlet - This was a pain, since a few are in hard to get places. As for the torque, all the bolts were screwdriver tight.
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/07removebolts.JPG

8) Unplug the lines
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/08linesunplugged.JPG

9) Support the tank - Important since you don't want the tank to just fall out
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/09supporttank.JPG

10) Unbolt Fastners - Again these were tight, but spanner tight
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/10tankfastner.JPG

11) Remove the Tank - the moment we ahve all be waiting for
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/11removetank.JPG

12) Tank is out!
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/12tankout.JPG

-==L=a=N=c=E==-
12-18-2004, 08:39 AM
Glory Shots
Fueltank - What fueltank?
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/removed.JPG

There it is!
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/tank.JPG

Now to find that fuel leak.

The little bastard!
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/hole1.JPG
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/hole2.JPG

The reason to why i have to drop the tank in the first place.

So in that case, it wasn't a leaky gasket, so for me to drop this tank off to get fixed ill have to remove everything.

Gaskets:
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/gaskets.JPG

All the internal stuff removed:
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/internals.JPG

And some close up shots of each part:
Evap Pipe : http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/evappipe.JPG
Pump: http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/pump1.JPG
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/pump2.JPG
Sender: http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/sender.JPG

And finally, i had to cover up the fuel filler neck, to stop the dust and stuff getting into it.
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/covered%20up.JPG

And a shot of inside the tank
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/insidetank.JPG

And thats it, took me approximately 2 hours to do, because i was taking my time. On the difficuilty scale, i found it relatively easy. I did have about 2 litres of fuel in the tank, which i poured out. I was also surprised to find rocks in the bottom of the tank. I did have one small mishap where i have accidently bent the return line out of shape, but it is easily bent back.

And thats it for now.

-==L=a=N=c=E==-
12-18-2004, 08:40 AM
I just went and cleaned the tank up, firstly i topped the tank full of water, and washed the outside of it.

More detailed shots of the damage
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/hole3.JPG
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/hole4.JPG
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/Out/hole5.JPG

-==L=a=N=c=E==-
12-18-2004, 08:40 AM
http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/In/gaskets.JPG
The new gaskets, and the gasket goo (fuel resistant)

http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/In/tankrepair.JPG
And the Repaired Tank. Not bad for $33 bucks.

The guys at the shop lost the little rubber pad, so ill have to bang up a new one, and glue it on. Apart from that im ready to put the tank in, just have to clean up the holes.

I've also sourced a SupraTT pump. Now i have to find a FPR so i can correct the fuel pressure. Or hopefully the FCon can trim the fueling a bit.

-==L=a=N=c=E==-
12-19-2004, 12:48 AM
Once the sun went down, and i couldn't fiddle with the battery and the intake anymore, i decided to prep the tank. I firstly cleaned it out of all the debris.

I decided to only mount the EVaporator pipe and the Sender controller, as i am waiting for my new pump. More on that later.

http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/In/clean%20holes.JPG
First you have to clean up the holes, this shot shows the cleaned up hole, and the other isn't clean (its kinda obvious, but the more silver one is the cleaned up one)

I thought i took a shot of the gaskets and the gasket goo, but my camera didn't take it :(

http://ugbox.net/~lance/GT4/Repair/Fuel%20Tank/In/isntalled.JPG
And this is with the parts installed. Now for the torque, i guessed, a) because i don't have a torque wrench, and b) its a phillips head screw bolt only. So i did it up hand tight. And will nip it up again when i work on them again.

After all that, i decided to pull the pump apart a) to clean it b) to upgrade the pump

http://ugbox.net/~lance/GT4/Modifications/Fuel%20Pump/fuelpump.JPG
http://ugbox.net/~lance/GT4/Modifications/Fuel%20Pump/removebracket.JPG
Remove the bottom from the bracket

http://ugbox.net/~lance/GT4/Modifications/Fuel%20Pump/removed.JPG
Unbolt everything

http://ugbox.net/~lance/GT4/Modifications/Fuel%20Pump/disassembled.JPG
And the pump dissambled. I didn't really go into depth on how to pull it part, as it is quite trivial.

But alas, i tried to clean the fuel filter out, but its clogged up, so ill purchase another one from toyota, along with this tiny tiny clip.
http://ugbox.net/~lance/GT4/Modifications/Fuel%20Pump/mustreplace.JPG

Snafu
12-23-2004, 12:11 AM
Nice man. You always have the greatest writeups ever. Congrats.

Rio_Cyber
01-17-2005, 08:40 AM
NICE WRITEUP, but i noticed that u can use some new busshings on your sway bar, and that was a perfect oportunity to get some bigger fuel pump (like walbro 255) in it.

btw. i have done that also and it is very simple job, if u have any sense for using a scredriwer and a wrench.

-==L=a=N=c=E==-
01-17-2005, 10:17 AM
Rio_Cyber:

Yes i know my sway bar bushes are a bit sad, but im saving up for a little while. for the whiteline kit.

As for the fuel pump, the original plan was to reaplce it with a Supra pump, but i got the JDM pump isntead, which isn't a direct fit.

It doesn't matter, if i need fueling upgrades, im going to go with a surge tank instead. Shoudl be plenty (and better ) for my power goals.

TRDmkII
01-18-2005, 04:26 AM
looking good, great write up, its sooo easy to change the fuel pump on these 5th gens, i think it took me all of 5 minutes...nice tank repair...never seen that done...

kinick313
01-18-2005, 07:40 PM
great write up! definitely sticky material

87toyost
02-11-2005, 03:42 PM
Very Good Detailed Write Up Keep Up The Good Work In The Future