Changing Fuel Tank on 1994 Toyota T100

I love the classics and most people wouldn’t put any money into the old trusty but rusty pickup trucks but I’m one of those guys that likes what I like.

So I have three issues with my 1994 Toyota T100 that I need to fix

  1. Leaking Fuel Tank at the seam (so half a tank and more it leaks)
  2. Timing (difficult to start but it always does)
  3. Emergency Brake (doesn’t exist which is difficult with a 5spd manual)

Here I am going to concentrate on the issue listed above that could blow me up which is the leaking gas tank.  I priced it out and everyone wants over a $1000 to replace the tank so it sounds like a job I will have to get done myself.

Tools needed for the job

  • Siphon (if you can’t just run the truck down on fuel)
  • Pliers
  • Floor jack
  • 4 jack stands
  • Socket wrench set
  • Torque wrench
  • Replacement fuel pump
  • Replacement fuel pump gasket
  • PB Blaster (help break up the rust)
  • Fuel Tank Straps (mine were pretty rusty so replacing)

If I’m going to replace the fuel tank its a perfect time to put a new fuel pump in as well since its located in the fuel tank since a faulty fuel pump can restrict fuel supply and keep your engine from running properly–or running at all.

Warnings
Exercise caution when working around fuel. Do not work near smoke, flames or extreme heat.

  1. Drive the vehicle or let the engine run until the fuel gauge reads very close to empty. If the fuel pump is inoperable and the vehicle won’t run, you will have to siphon the fuel out of the fuel tank.
  2. Relieve the pressure from the fuel lines. Remove the fuel pump relay from the engine bay fuse box, remove the fuel filler cap and crank the vehicle. Let it run until the engine sputters and dies. The fuel system is under intense pressure; it must be relieved before performing the procedure.
  3. Disconnect the negative battery cable with the pliers. Lift the vehicle from the front first, using the factory jacking point between the front axle. Support the front with two jack stands. Repeat to lift and support the rear.
  4. Remove the fuel lines from the tank and cap them off to prevent leaking. Even after you have relieved fuel system pressure there will still be a small amount of fuel in the lines. Remove the fuel filler connection and the vent lines.
  5. Remove the fuel tank support brackets then support the fuel tank with the floor jack. Remove the bolts mounting the fuel tank. Once the bolts are removed, have a helper slowly let the jack down while you support the sides of the fuel tank. Be careful not to spill fuel. Even if you have siphoned the fuel out, there will likely be a couple of gallons left in reserve.
  6. Install the new gasket and mount the new fuel pump on the new gas tank. Use the torque wrench to tighten the pump bolts to 35 foot-pounds.
  7. Lift the fuel tank into its mounting position. Have a helper provide support with the jack, but do not rely solely on the jack. Tighten the mounting bolts on the fuel tank, then remove the jack.
  8. Reattach the fuel filler connection, vent lines and fuel lines. Reattach the support brackets. Lower the vehicle and replace the fuel pump relay and the fuel filler cap. Connect the negative battery cable and start the engine to check for leaks.
  9. Add a sufficient amount of fuel before cranking the engine.

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