Fuel Tank and Pump Removal/Repair Tutorial

Hey all! Had some starting issues a couple months ago on the ‘06 4.0 and narrowed it down to a fuel delivery issue. Ended up yanking the fuel tank and pump to find out the potentiometer on the fuel sending float had a dead spot in it. Gauge showed I had gas when, in fact, there was none in the tank. I videoed the process for those of you needed direction on how to remove both, and it’s uploaded here for your convenience. Hope it helps someone!

https://youtu.be/HIrTIrzQUPE

 

Nice video. I didn't see the sock filter. Where is it located

 

The first official fuel 'filter' is upstream of the tank, I think under the driver door area. There is a screen inside the pump, but I wouldn't call it a true serviceable filter.

 

The fuel pump's sock filter was inside the fuel sending unit. Inside the "bowl" if you will. The outlet of the pump is then plugged into the fuel filter. The outlet of the fuel filter goes into the black accordion tube.

 

Those quick disconnects... is there not a special tool to release them? It isn't clear from the video what exactly you are doing to get them with the channel lock pliers without breaking them. Great video, BTW!

 

I would imagine there is a special tool Toyota uses on them. They were tricky with the channel locks, but not impossible. Squeeze button on each side.

 

Great video I'm going to hopefully be able to do this in one day tomorrow lol

 

Fantastic video, thanks for posting!

 

Thank you; only place I could find info on removing that hard-to-reach cap on the tank. Going out now to get it done - putting a gas Webasto heater in the Taco.

 

hi! bringing this back with a question - anyone have a guide or tips for reinstallation? my fuel tanks got a big hole and I need to replace it.