Gas Tank Replacement Journey

[Kmurt]

2001 4Runner 254,500 miles

There are videos and write ups on how to drop the tank so I will not cover that here.

Parts List:
-SPECTRA PREMIUM TO33B Gas tank
-Fuel Pump (DENSO) – 950-0100
-Hose, Fuel Tank Vent - 77404-35010
-Fuel Tank Overfill Check Valve - 77390-35010
-Fuel Tank Overfill Check Valve Gasket - 77177-33010
-Fuel Shut-Off Solenoid - 77380-26010
-Fuel Shut-Off Solenoid Gasket - 77179-26011
-Suction Tube - 77203-35660
-Sending Unit - 83320-35620
-Connector Hose - 77213-35360

Couple of years ago I would throw a Check Engine Light for EVAP codes P0440, P0441, and P0446. Since my inspection wasn't due I would just clear the codes and continue on my way.

This past October I was due for inspection and of course I wait last minute to do anything about it. I tried the cheapest/easiest option of swapping in a new OEM gas cap, no luck. I have read tons of threads on these codes and finally decided that it was probably time to replace everything on the gas tank because everything was original and upon inspection it looked like everything was crusty and old. Also, the 96-00 gas tank components are different then 01-02 and of course with mine being an 01, there is a little more involved.

I kinda had an idea of what I was getting into because I figured I might as well just drop the gas tank because that is the only way I'm going to be able to replace everything. Keep in mind this 4runner had spent its whole life in NJ. This is where I started to head down the rabbit hole.

I replaced everything I could associated with the fuel tank including new fuel pump, suction tube, sending unit, gaskets. Did not want to have to do this job again for a long time.

Top of the tank:
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When I was diconnecting those three vent hoses on top of the tank, the one that is attached to the metal 90 snapped right off. Hmm I guess that was probably one of my problems.

After disconnecting everything I dropped the tank down and look what was hiding behind it:
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Remember I said about going down the rabbit hole? Well here we are. I have read plenty of dreaded frame rust threads and how the lower control arm mount will just rust off and I finally got to see it first hand. Thankfully it could be fixed and I did have it fixed.

So now I finally have the tank out from under the car and can look over everything. Lots of dirt and rust at the top of the tank. I came to the conclusion that this tank is pretty much shot and I don't feel like chasing anymore possible issues with it.
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Here is the inside of the OEM tank
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I decided to buy the SPECTRA PREMIUM TO33B gas tank off of Rock Auto since Toyota no longer sells the OEM tank. It was recommended by another forum member here that had said it looked OEM and fit without issue.

Here is how it arrived
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And the inside which is a little bit different than OEM
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[Kmurt]

Part 2

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Installing all the new parts was pretty straight forward and I even replaced the rubber hoses with new ones and installed all new clamps. Also added an adhesive piece of foam where the tank butts up to the top of the metal bracket under the car. I painted Fluid Film all over the tank to help it from corroding.

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New suction tube, fuel pump, sending unit and gasket.
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An absolute pain to hook up the 3 rubber vent hoses to the hard lines especially since the metal 90 vent line on the new tank is a little longer and not as much on an angle as the old 90. This was definitely the hardest part for me because I also had to angle the gas tank to just install that one line.

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Here it is installed. Messy but finally done. I didn't bother to order a new gas tank strap since mine was in good condition still.

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I was so relieved when I turned it over and it started. I drove around 100 miles and I had no Check Engine Light! I have a ScanGauge and it said the evap system was ready without any codes so I headed over to the inspection station and passed! Hopefully this helps anyone that is in the same situation as I was.

 

[shadow247]

How do you like the Spectra Tank. I bought a used tank for 100 bucks, but i'm not sure if I'm willing to spend the time/money to clean it up for install.

I need a new one because my current tank has a giant dent from slamming into rocks.

 

[Kmurt]

How do you like the Spectra Tank. I bought a used tank for 100 bucks, but i'm not sure if I'm willing to spend the time/money to clean it up for install.

I need a new one because my current tank has a giant dent from slamming into rocks.

So far so good! Looks identical to OEM aside from the sump and the baffles inside the tank.

Is the tank you bought used an OEM tank?

 

[OpenYota]

What was your trick for getting the flex hose off from the charcoal canister to the check valve lol

That was the worst part of the whole job for me

 

[96RedRunner]

Missed a spot with the fluid film, :biggrin1:

Good timing having to pull tank, lower link mount seen better days. Got any plans?

 

[mtbtim]

For anyone looking for a video on how to remove and reinstall a fuel tank, here you go.

<iframe width="560" height="315" src="https://www.youtube.com/embed/GrzX_K-jcuo?si=4vIVTiVjLE49MQod" title="YouTube video player" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" allowfullscreen></iframe>

 

[Kmurt]

What was your trick for getting the flex hose off from the charcoal canister to the check valve lol

That was the worst part of the whole job for me

I first took it off from where it attached to the charcoal canister itself which was way easier to get to then from on top of the tank.

Thanks to past mechanics, the fitting that you are supposed to squeeze to pull the hose off was broken already so it didn't come off with too much fight. I left the gas tank side connected because it was too much of a pain to take off in that tight of an area.

 

[Kmurt]

Missed a spot with the fluid film, :biggrin1:

Good timing having to pull tank, lower link mount seen better days. Got any plans?

If by plans you mean getting the mount fixed, then yes I did have a new piece welded in. Can't even tell it was fixed. The shop that I took it to did a really good job.

The shop went a little overkill spraying black WoolWax all over the place but at least for now it is protected for the winter. I might go back and hose it all off and do it myself with Fluid Film. I don't really care for the "black" look.

 

[Kmurt]

For anyone looking for a video on how to remove and reinstall a fuel tank, here you go.

<iframe width="560" height="315" src="https://www.youtube.com/embed/GrzX_K-jcuo?si=4vIVTiVjLE49MQod" title="YouTube video player" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" allowfullscreen></iframe>

This was one of many videos I used as a guide for this project.

Thanks Tim.

 

[shadow247]

So far so good! Looks identical to OEM aside from the sump and the baffles inside the tank.

Is the tank you bought used an OEM tank?

Yeah it's really clean on the outside, but has a little crustiness inside. It's been stored inside for the past 2 years after being pulled off a super clean wreck. Unfortunately he didn't drain the fuel, so it really needs to be cleaned and possibly relined. Its only 280 dollars at the local hot rod shop, so that's probably the route I'm going to go.

 

[Kmurt]

Yeah it's really clean on the outside, but has a little crustiness inside. It's been stored inside for the past 2 years after being pulled off a super clean wreck. Unfortunately he didn't drain the fuel, so it really needs to be cleaned and possibly relined. Its only 280 dollars at the local hot rod shop, so that's probably the route I'm going to go.

I would keep the OEM and have it cleaned up.

And for peace of mind, just order new parts like I have so you won't have to worry about it for a long time.

 

[96RedRunner]

[MENTION=118736]Kmurt[/MENTION] I'm having to do tank drop for all but tank replacement myself.
Figure it a good time to weld on the eimkeith LLS's that I've had for 3-4 yrs.

 

[Kmurt]

[MENTION=118736]Kmurt[/MENTION] I'm having to do tank drop for all but tank replacement myself.
Figure it a good time to weld on the eimkeith LLS's that I've had for 3-4 yrs.

Good luck. That would be the time to weld those in with all of that extra room.

 

[Kmurt]

UPDATE

1000 miles later and no CEL or anything abnormal.

I'd say this was a success!

 

[faizy1390]

Can you please share from where did you get the Denso Fuel Pump? It would be great if you can share a picture of the box packing showing the part number and its country of manufacture. I am looking to replace the fuel pump on my 2001 Hilux Surf (RHD 4Runner) but I am not exactly sure whether to opt for Original Toyota Part or go with Denso 950-0100. I read somewhere that Denso pumps coming with part number 950-0100 are made in China now. Since you have done the replacement recently, I was wondering if you can confirm whether it was made in China or Japan.

 

[AuSeeker]

Can you please share from where did you get the Denso Fuel Pump? It would be great if you can share a picture of the box packing showing the part number and its country of manufacture. I am looking to replace the fuel pump on my 2001 Hilux Surf (RHD 4Runner) but I am not exactly sure whether to opt for Original Toyota Part or go with Denso 950-0100. I read somewhere that Denso pumps coming with part number 950-0100 are made in China now. Since you have done the replacement recently, I was wondering if you can confirm whether it was made in China or Japan.

To get his attention so he can answer your question I will "mention" him.... [MENTION=118736]Kmurt[/MENTION] which will notify him.

 

[faizy1390]

Thank you

 

[TheDurk]

Can you please share from where did you get the Denso Fuel Pump? It would be great if you can share a picture of the box packing showing the part number and its country of manufacture. I am looking to replace the fuel pump on my 2001 Hilux Surf (RHD 4Runner) but I am not exactly sure whether to opt for Original Toyota Part or go with Denso 950-0100. I read somewhere that Denso pumps coming with part number 950-0100 are made in China now. Since you have done the replacement recently, I was wondering if you can confirm whether it was made in China or Japan.

I assume you know that Denso made the original fuel pimps for Toyota. So if new Denso pumps are now made in China, as soon as Toyota and their dealer network use up stock on hand, the "Original Toyota Part" will be made in China, too.

 

[dell30rb]

Nice write up