This procedure covers the removal and replacement of the fuel tank retention straps on a 2018-2024 Toyota Camry with the 2.5L I4 engine, including fuel system depressurization and tank lowering.

Warnings

Tools required

Parts

• Fuel tank strap (driver side) × 1 — Toyota 77516-06010 or equivalent
• Fuel tank strap (passenger side) × 1 — Toyota 77516-06020 or equivalent
• Fuel line O-rings × 4 — Use OEM specification
• Fuel filler neck seal × 1 — Use OEM specification

Preparation

1. Park vehicle on level concrete surface outdoors or in well-ventilated garage with no ignition sources within 50 feet
2. Place fire extinguisher within immediate reach of work area
3. Ensure fuel level is below 1/4 tank. If above 1/4 tank, drive vehicle to consume fuel or use approved fuel transfer pump to drain into approved containers
4. Disconnect negative battery terminal and isolate cable away from battery post
5. Remove fuel pump fuse (EFI MAIN, 30A in engine bay fuse box) and attempt to start engine to depressurize fuel system. Engine will run briefly then stall
6. Raise vehicle using floor jack and support on jack stands at all four factory jacking points. Vehicle must be level and secure
7. Allow exhaust system to cool completely (minimum 2 hours after driving)
8. Chock front wheels securely

Procedure

1. 1

   Access fuel tank area
   From under the vehicle, locate the fuel tank positioned ahead of the rear axle. Remove the plastic fuel tank protective cover if equipped by removing the push clips and cover screws. Inspect the work area and identify the two fuel tank straps running transversely under the tank, fuel filler neck on driver side, fuel lines and electrical connector on top of tank.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
2. 2

   Disconnect fuel filler neck
   Locate the fuel filler neck connection at the driver side of the tank. Loosen the hose clamp securing the filler neck to the tank inlet using a flathead screwdriver or socket. Carefully twist and pull the filler neck away from the tank. Inspect the rubber seal and replace if cracked or damaged. Be prepared for residual fuel spillage.
   ⚠Residual fuel will drain from filler neck. Position drain pan underneath before disconnecting.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect fuel tank breather hose
   Locate the evaporative emissions breather hose connected near the filler neck. Release the hose clamp and disconnect the breather hose from the tank. Allow any residual fuel to drain into the drain pan.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect fuel supply and return lines
   Locate the fuel supply line and return line connections at the top of the fuel tank. Using the appropriate fuel line disconnect tool, press the tabs to release the quick-connect fittings and disconnect both fuel lines. Cap or plug the lines immediately to prevent fuel spillage and contamination. Inspect O-rings and discard for replacement with new parts.
   ⚠️Residual fuel pressure may remain despite depressurization. Cover connection with shop towel when disconnecting to contain fuel spray.
5. 5

   Disconnect electrical connector
   Locate the fuel pump and sender unit electrical connector at the top of the tank. Press the locking tab and disconnect the electrical connector. Secure the connector away from the work area to prevent damage.
6. 6

   Support fuel tank
   Position a transmission jack or adjustable floor jack with wide platform directly under the center of the fuel tank. Raise the jack until it just contacts the tank and provides light support. Place a block of wood between the jack and tank to distribute load and prevent damage. The jack must be stable and centered to prevent the tank from shifting when straps are released.
   ⚠️Tank must be securely supported before loosening strap bolts. Tank can fall suddenly when straps are released, causing serious injury.
7. 7

   Apply penetrating oil to strap hardware
   Spray penetrating oil on all four fuel tank strap mounting bolts (two bolts per strap, located at each end of each strap). Allow 10-15 minutes for penetration. These bolts are frequently corroded due to road salt and moisture exposure.
8. 8

   Remove passenger side fuel tank strap
   Beginning with the passenger side strap, use a socket and ratchet to slowly loosen both mounting bolts that secure the strap to the vehicle chassis. Support the strap as you remove the second bolt to prevent it from falling. Remove the strap and inspect for corrosion, cracking, or deformation. Replace if any damage is present.
   ⚠Strap is under tension and may snap toward you when bolts are loosened. Keep hands clear of strap path.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
9. 9

   Remove driver side fuel tank strap
   While maintaining tank support with the jack, loosen and remove both mounting bolts from the driver side strap. As you remove the final bolt, be prepared for the tank to shift slightly. Lower the tank 2-3 inches on the jack and verify all connections have been disconnected. Remove the driver side strap and inspect for damage.
   ⚠️This is the final strap supporting the tank. Ensure jack is securely positioned and stable before removing final bolts.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Inspect and prepare mounting points
    With straps removed, inspect the fuel tank mounting surface and chassis mounting points for corrosion, damage, or deformation. Clean mounting surfaces with a wire brush. Apply a light coating of anti-seize compound to the chassis mounting bolt threads (not the bolt heads). Inspect new straps for proper fit and orientation before installation.
11. 11

    Install new fuel tank straps
    Raise the fuel tank using the jack until it is approximately 1 inch below its final mounting position. Position the new driver side strap over the tank and align with the chassis mounting holes. Start both mounting bolts by hand and tighten finger-tight. Repeat process for passenger side strap. Ensure straps are properly seated in the tank grooves and not twisted.
12. 12

    Torque strap mounting bolts
    Using a torque wrench, tighten all four strap mounting bolts to specification in a cross pattern (driver front, passenger rear, driver rear, passenger front). Verify the tank is centered and level in the chassis. The tank should not move when pushed gently.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
13. 13

    Reconnect fuel lines with new O-rings
    Install new O-rings on both the fuel supply line and return line fittings. Lightly lubricate the O-rings with clean gasoline. Push each quick-connect fitting onto the tank connection until you hear and feel a positive click. Gently pull on each line to verify secure connection.
    ⚠Never reuse old fuel line O-rings. Degraded O-rings will leak and create fire hazard.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
14. 14

    Reconnect remaining connections
    Reconnect the fuel pump electrical connector ensuring the locking tab clicks into place. Reconnect the fuel filler neck to the tank inlet with new seal if original showed damage. Position the hose clamp and torque to specification. Reconnect the breather hose and secure with hose clamp to specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
15. 15

    Reinstall protective cover
    If equipped, reinstall the fuel tank protective cover and secure with cover screws torqued to specification. Carefully lower and remove the transmission jack from under the vehicle. Inspect the entire work area for tools or parts left behind.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Reconnect negative battery terminal
2. Reinstall fuel pump fuse (EFI MAIN, 30A)
3. Before lowering vehicle, perform final visual inspection of all connections and torque values
4. Lower vehicle from jack stands

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump priming (2-3 second hum from rear of vehicle). Cycle ignition off and on three times to pressurize fuel system
• Immediately inspect all fuel line connections, filler neck, and breather hose for fuel leaks. Look for drips and smell for gasoline vapors
• Start engine and allow to idle for 5 minutes while monitoring for leaks. Check underneath vehicle with work light for any fuel drips
• Take vehicle for short test drive (5 minutes) and re-inspect all connections after drive. Any fuel odor or visible leaks require immediate repair before further operation
• Monitor for fuel odors during first 100 miles of operation. Any persistent fuel smell indicates a leak that must be addressed immediately

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