Rajan Wilcox
The Toyota Hilux is known for its ruggedness and reliability, but even these tough trucks need regular maintenance. Removing the fuel tank from a Hilux is a process that requires multiple steps. Before starting, it is important to siphon out as much petrol from the tank as possible. This is followed by disconnecting the battery and removing bolts and hose clamps. Once the tank is out, the fuel pump can be accessed and replaced. It is important to note that there are variations in the process depending on the model year and type of Hilux.
Characteristics and Values Table for Removing Fuel Tank from Hilux
| Characteristics | Values |
|---|---|
| First Step | Disconnect the battery, and if you have a dual system, disconnect them as well. |
| Second Step | Use jerry cans to siphon out as much petrol from the tank as possible. |
| Third Step | Remove the front three bolts and the bottom three bolts at the rear, then carefully remove the rock guard. |
| Fourth Step | Loosen the remaining bolts at the front and rear, without removing them. |
| Fifth Step | Loosen the hose clamp on the main filler fuel pipe and the thinner pipe next to it. |
| Sixth Step | Slowly lower the fuel tank to the ground, using a funnel to drain the remaining fuel into a jerry can. |
| Seventh Step | Refit the tank by screwing in one of the front bolts and connecting the pipes. |
| Eighth Step | Re-fill the fuel tank with fuel, ensuring the vehicle is earthed to the ground to prevent static electricity and explosions. |
| Tools and Equipment | Wrench set, adjustable wrench, funnel, jerry cans, safety glasses, gloves, fuel line disconnect tool, fuel line clamps, container for fuel. |
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What You'll Learn
Disconnect the battery and siphon fuel
Disconnecting the battery and siphoning the fuel are crucial steps in removing the fuel tank from a Hilux. Here is a detailed guide on how to safely and effectively complete these steps:
Disconnect the Battery
Before beginning any work on your Hilux, it is essential to disconnect the battery as a safety precaution. This step is crucial, especially when dealing with fuel and flammable liquids. Turn off the engine and locate the battery, typically found in the engine bay. Disconnect the negative terminal first, followed by the positive terminal, using the appropriate tools and safety gear. Ensure that the battery is securely disconnected before proceeding to the next step.
Prepare for Siphoning
To siphon fuel safely, you will need the following equipment: a length of tubing, a receptacle (such as a jerry can or fuel container), and possibly a pair of pliers. Ensure that the tubing is long enough to reach from the fuel tank to the ground, where you will place your receptacle. It is recommended to use clear tubing so you can monitor the fuel flow and prevent accidental ingestion of fuel, which is hazardous to your health.
Siphon the Fuel
Locate the fuel tank, typically found beneath the vehicle near the rear wheels. To access the fuel, you can either remove the fuel filler cap or locate the rubber hose connected to the top of the tank from the filler tube. If removing the filler cap, ensure the area is well-ventilated to avoid inhaling fumes. If using the rubber hose method, remove the hose clamp with a suitable tool, such as a small ratchet. Insert one end of the tubing into the filler tube or the opening where the hose was connected, ensuring it reaches the bottom of the tank. You may need to blow air into the other end of the tube and listen for bubbles to confirm it is submerged in the fuel.
Once the tubing is securely in place, you can begin siphoning. There are several methods to start the fuel flow, including using a mechanical air pump or blowing with your lungs (be extremely cautious to avoid inhaling fumes). If using lung power, create a tight seal around the tube and blow air into the tank, increasing the pressure and causing the fuel to flow through the tube into your receptacle. Monitor the flow, and once the fuel is moving freely, gravity will do the rest. Remember to control the flow and cover the tube when you have siphoned enough fuel to prevent overflow.
Safety and Legal Considerations
It is important to note that siphoning fuel can be dangerous and is illegal in some areas. Always exercise caution, follow safety procedures, and ensure you have permission to siphon fuel if it is not your own vehicle. Avoid smoking or any activity that could create sparks or flames during the entire process. Finally, properly store the siphoned fuel in a safe location, away from any potential sources of ignition.
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Remove bolts and rock guard
To remove the bolts and rock guard, you will need to first disconnect the battery. If you have a dual system, disconnect them as well. Use jerry cans to siphon out as much petrol from the tank as possible. There will be six 12mm head spanner bolts at the front and six 12mm headed bolts at the rear. Remove the front three bolts and then the bottom three at the rear. You can then remove the rock guard. Be careful that it does not fall on you when you loosen the last bolt.
The rock guard is a protective cover for the fuel tank. It is important to remove it carefully to avoid any damage to the fuel tank or the guard itself. Once the rock guard is removed, you will be able to access the fuel tank and proceed with the next steps of the fuel tank removal process.
It is crucial to take the necessary safety precautions when performing any maintenance or repair work on your vehicle. Make sure to work in a well-ventilated area and wear appropriate protective gear, including gloves and safety glasses. Ensure that there are no sources of ignition nearby, such as lit cigarettes or open flames, as petrol is highly flammable.
Additionally, it is important to properly dispose of the petrol that you siphon from the tank. Petrol is a hazardous substance and must be handled and disposed of responsibly. Check with your local regulations or waste management services for the correct disposal methods in your area.
By following these steps and taking the necessary safety precautions, you can safely remove the bolts and rock guard, allowing you to access the fuel tank for further maintenance or repairs.
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Loosen hose clamps and pipes
To loosen the hose clamps and pipes when removing the fuel tank from a Hilux, you will need to first disconnect the battery. Then, siphon out as much petrol from the tank as possible. Next, remove the rock guard by unscrewing the front three bolts and then the bottom three at the rear. Be careful not to let the rock guard fall on you as you loosen the last bolt.
Now, you will see three bolts in front and three at the rear. Loosen these bolts, but do not remove them yet. At this point, you will need to loosen the hose clamp on the main filler fuel pipe. Next to this pipe, you will see a thinner pipe—loosen it as well. You will also need to disconnect the fuel lines from the old filter using a fuel line disconnect tool. This step is crucial as it releases the pressure in the fuel system.
Once the hose clamps and pipes are loose, you can slowly lower the fuel tank to the ground. Use a funnel to drain out the remaining fuel into a jerry can or another suitable container. Ensure that you store the fuel in a safe place.
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Lower the fuel tank
To lower the fuel tank of a Hilux, you must first drain the tank. Disconnect the battery, and if you have a dual system, disconnect them as well. Use a jerry can to siphon out as much petrol from the tank as possible.
Next, remove the front three bolts and the bottom three bolts at the rear. You can then remove the rock guard. Be careful that it does not fall on you when you loosen the last bolt. You will now see three bolts in front and three at the rear. Loosen these bolts but do not remove them yet. Loosen the hose clamp on the main filler fuel pipe, and next to this pipe, you will see a thinner pipe. Loosen it off as well.
Now you can slowly lower the fuel tank to the ground. Use a funnel to drain out the rest of the fuel that is in the tank into a jerry can. Make sure you store the fuel in a suitable place that is safe. Do not smoke while doing this job.
Once the tank is out, you can access the fuel pump. The large centre ring has the fuel pump, which can be removed by turning the white ring counter-clockwise to the left. The fuel pickup will lift out, and then you can replace the pump and screen.
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Refit the tank and reconnect the battery
When refitting the fuel tank, it is important to follow a specific procedure to ensure a secure and proper installation. Here is a detailed guide on how to correctly refit the fuel tank and reconnect the battery in a Hilux:
Firstly, screw in one of the front bolts to hold the front of the tank in place. This will allow the tank to slope towards the rear, providing the necessary angle for connecting the pipes. Ensure that all the pipes have the correct pinch clamps and that they are positioned correctly.
Next, connect the breather pipe and the inlet large ID fuel pipe. Once you are satisfied that all the pipes are secure and properly attached, lift the other end of the tank and bolt it into place. Remember to reconnect any additional components, such as the small pipes mentioned earlier.
Now, you can refill the fuel tank with fuel. For safety reasons, it is recommended to earth the vehicle to a ground earth. This can be done by driving a copper rod into the ground and attaching a cable to one end, with the other end connected to the chassis of your vehicle. This step is crucial as static electricity can cause an explosion when petrol is poured into the vehicle.
Finally, reconnect the battery. After reconnecting the battery, the vehicle might take a few seconds for the fuel to reach the system. Ensure that you follow the correct safety procedures and refer to your vehicle's manual if needed.
By following these steps, you can securely refit the fuel tank and reconnect the battery in your Hilux, ensuring a safe and proper functioning vehicle.
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Frequently asked questions
Here is a step-by-step process to remove the fuel tank from your Hilux:
- Disconnect the battery.
- Siphon out as much petrol from the tank as possible.
- Remove the front three bolts and the bottom three bolts at the rear.
- Remove the rock guard.
- Loosen the remaining bolts at the front and rear without removing them.
- Loosen the hose clamp on the main filler fuel pipe.
- Lower the fuel tank to the ground and drain out the remaining fuel into a jerry can.
You will need the following tools to remove the fuel tank from your Hilux:
- Jerry cans
- 12mm head spanner
- Funnel
- Wrench set
- Adjustable wrench
- Rag or shop towels
- Safety glasses
- Gloves
- Fuel line disconnect tool
- Fuel line clamps
- Container for fuel
Here are some important precautions to take when removing the fuel tank from your Hilux:
- Ensure you are in a well-ventilated area and do not smoke while performing this task.
- Be careful when removing the rock guard as it may fall.
- Store the fuel in a suitable and safe place.
- Ensure you are wearing safety glasses and gloves to protect your eyes and hands.
To reinstall the fuel tank in your Hilux, follow these reversed steps:
- Screw in one of the front bolts to hold the front of the tank in place, allowing it to slope towards the rear.
- Connect the various pipes, ensuring the correct pinch clamps are in the right positions.
- Connect the breather pipe and the inlet large ID fuel pipe.
- Lift the other end and bolt it into place, remembering to include the small spacer bracket at the rear.
- Reconnect the battery and start the vehicle.
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