Fuel Tank

This procedure covers removal and installation of the fuel tank on a 2012-2017 Toyota Camry with the 2.5L I4 engine, including depressurizing the fuel system, disconnecting fuel lines, and lowering the tank from the vehicle.

Warnings

Tools required

Parts

• Fuel tank assembly (if replacing) × 1 — 77001-06221 or equivalent OEM
• Fuel tank strap set × 1 — Use OEM specification if damaged
• Fuel line O-rings × 4 — 90301-10010 or equivalent
• Filler neck hose clamp × 1 — Replace if damaged
• Fuel pump assembly gasket/seal × 1 — 77168-06010 or equivalent

Preparation

1. Park vehicle on level surface in well-ventilated area away from ignition sources
2. Ensure fuel tank is less than 1/4 full; drain excess fuel if necessary using approved transfer pump
3. Disconnect negative battery cable and wait 90 seconds for airbag system to depressurize
4. Remove fuel pump fuse (EFI1 30A in engine compartment fuse box) or fuel pump relay
5. Start engine and allow it to run until it stalls to depressurize fuel lines
6. Attempt to start engine 2-3 more times to ensure fuel pressure is relieved
7. Raise vehicle on lift or support securely on jack stands at all four corners at manufacturer-specified lift points
8. Remove rear wheels if additional working clearance is needed
9. Place fire extinguisher within reach and ensure adequate ventilation

Procedure

1. 1

   Remove rear seat cushion for fuel pump access
   From inside the vehicle, locate the two clips at the front edge of the rear seat cushion. Pull firmly upward at the front edge to release the clips and remove the seat cushion. This provides access to the fuel pump service cover.
2. 2

   Remove fuel pump access cover
   Locate the rectangular access cover in the floor pan beneath where the rear seat was. Remove the cover screws using a Phillips screwdriver. Carefully lift the cover and set aside. You will see the fuel pump assembly top with electrical connector and fuel lines attached.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Disconnect fuel pump electrical connector and fuel lines
   Disconnect the electrical connector from the fuel pump assembly by pressing the locking tab and pulling straight up. Using the appropriate fuel line disconnect tool, disconnect the fuel feed and return lines from the pump assembly. Be prepared for residual fuel spillage; use shop rags to catch fuel. Cap or plug the disconnected lines to prevent contamination.
   ⚠Even after depressurization, residual fuel will be present. Keep rags and drain pan ready.
4. 4

   Remove exhaust heat shield and hanger
   From under the vehicle, locate the exhaust heat shield above the fuel tank. Remove the mounting bolts securing the heat shield and carefully lower it. If necessary, support the exhaust system with a stand and disconnect the rubber hanger near the fuel tank area to provide clearance for tank removal.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
5. 5

   Disconnect fuel filler neck and vent hoses
   Locate the fuel filler neck connection at the rear driver side of the tank. Loosen the hose clamp securing the filler neck to the tank using a flathead screwdriver or appropriate tool. Disconnect the filler neck hose from the tank. Also disconnect the evaporative emission vent hoses from the tank, noting their positions for reinstallation. Use the fuel line disconnect tool for quick-connect fittings.
   ⚠Fuel may drain from the filler neck when disconnected. Position drain pan accordingly.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
6. 6

   Disconnect EVAP and fuel line connections
   Working from under the vehicle, locate all remaining fuel lines and EVAP lines connected to the fuel tank. This typically includes the main fuel supply line, fuel return line (if equipped), and EVAP canister lines. Use the appropriate fuel line disconnect tools to release each quick-connect fitting. Label or photograph connections to ensure correct reassembly. Allow residual fuel to drain into your drain pan.
   ⚠Keep track of all line connections and their orientations. Take photos before disconnecting if needed.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
7. 7

   Position transmission jack under fuel tank
   Position a transmission jack or adjustable jack stand with a wide piece of wood on top directly under the center of the fuel tank. Raise the jack until it just makes contact with the tank and provides slight support, but do not lift the tank yet. Ensure the jack is stable and centered to prevent the tank from shifting during removal.
   ⚠️The fuel tank is heavy and awkward. Ensure jack is properly centered and stable before proceeding.
8. 8

   Remove fuel tank strap bolts
   Locate the two fuel tank strap bolts at the rear of the tank. These bolts secure the metal straps that hold the tank to the vehicle chassis. Using a 14mm socket and ratchet, remove both strap bolts completely. The straps will pivot down once the bolts are removed. Support the tank with the jack as you remove the second bolt.
   ⚠️Ensure jack is supporting tank weight before removing the second strap bolt, as tank will be free to drop.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
9. 9

   Lower fuel tank from vehicle
   With the straps released and jack supporting the tank, carefully lower the jack while guiding the tank down and toward the rear of the vehicle. Watch for any remaining hoses or wiring that may still be connected. Angle the tank as needed to clear the rear subframe and exhaust components. Once clear of the vehicle, lower the tank completely onto a stable surface.
   ⚠Lower the tank slowly and watch for any remaining connections or obstructions. Have an assistant help guide the tank if possible.
10. 10

    Remove fuel pump assembly (if servicing tank or pump)
    If replacing the tank or servicing the fuel pump, remove the fuel pump assembly from the top of the tank. Use a brass punch and hammer to turn the locking ring counterclockwise (do not use steel tools that could create sparks). Once the ring is loose, remove it completely. Carefully lift the fuel pump assembly out of the tank, tilting it to avoid damaging the float arm and fuel level sender. Remove and discard the old gasket/seal.
    ⚠️Use only non-sparking brass tools when working directly on the fuel tank to prevent ignition risk.
    ⚠The fuel pump assembly is delicate. Handle carefully to avoid damaging the float arm or fuel level sender.

Reassembly

1. If fuel pump was removed, install new gasket/seal on tank opening and carefully install fuel pump assembly, ensuring float arm clears tank opening
2. Install fuel pump locking ring and torque to specification using brass punch, turning clockwise until tight
3. Position fuel tank on transmission jack and raise into approximate position under vehicle
4. Guide tank into place, ensuring filler neck and all line connections align properly
5. Install fuel tank straps and install strap bolts finger-tight initially
6. Torque tank strap bolts to specification: 35.0 Nm (26 lb-ft) in a cross pattern
7. Remove transmission jack once straps are secured
8. Reconnect all EVAP lines and fuel lines to tank using new O-rings on all fittings; torque fuel line fittings to 25.0 Nm (18 lb-ft)
9. Connect filler neck hose to tank and secure with new clamp if needed; torque filler neck clamp to 4.0 Nm (3 lb-ft)
10. Reconnect exhaust hanger and install heat shield with mounting bolts torqued to 27.0 Nm (20 lb-ft)
11. From inside vehicle, reconnect fuel feed and return lines to fuel pump assembly using new O-rings
12. Reconnect fuel pump electrical connector ensuring it locks securely
13. Install fuel pump access cover and torque screws to 11.0 Nm (8 lb-ft)
14. Reinstall rear seat cushion by engaging clips at front edge
15. Reinstall rear wheels if removed and torque to manufacturer specification
16. Reinstall fuel pump fuse or relay
17. Reconnect negative battery cable

Verification

• Turn ignition to ON position (without starting) for 2 seconds, then OFF. Repeat 3-4 times to prime fuel system and pressurize lines
• Inspect all fuel line connections, filler neck, and tank area for any signs of fuel leakage
• Start engine and allow to idle; check again for fuel leaks at all connection points
• Check that fuel gauge reads correctly and matches actual fuel level
• Take vehicle for short test drive and recheck all connections for leaks after vehicle has been driven
• Verify no fuel odor is present inside or outside vehicle
• Clear any diagnostic trouble codes if check engine light is illuminated due to fuel system being depressurized

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