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Toyota 4Runner 1996-2002 factory workshop and repair manual download

- Safety first
- Work outside or in a well-ventilated area away from flames, sparks, or anything that can ignite fuel vapor.
- Wear chemical-resistant gloves, eye protection, and long sleeves. Keep a rated ABC fire extinguisher nearby.
- Disconnect the negative battery terminal before you start work to reduce spark risk.
- Have absorbent rags, a small sealed container for spilled fuel, and a means to clean up spills (absorbent pads).

- How to identify whether your 4Runner has a serviceable external fuel filter
- Visual check: look along the driver-side frame rail and fuel line from tank to engine. An external can-style inline filter (metal or plastic cylinder) is typically mounted in a clamp along the frame or firewall on older models (commonly pre-mid-2000s).
- If there is no external filter and the fuel lines go directly to a fuel pump module at the tank, your model likely has an in-tank filter/sock integrated with the fuel pump (common on newer 4Runners). In-tank filters generally require removing the fuel pump module or replacing the module — not a simple “filter swap.”

- Parts you might need and why
- Replacement fuel filter (explicitly matched to your model year and engine): required if you have an external, serviceable filter. Filters are directional — install with the arrow pointing toward the engine (fuel flow).
- Fuel pump module (assembly) or in-tank filter sock: required if your vehicle uses an integrated in-tank unit and the filter is clogged or the pump failing. This is a bigger repair and often recommended as a matched OEM or aftermarket pump assembly.
- New fuel line O-rings or quick-connect collars: these often degrade and should be replaced to prevent leaks.
- New clamps (worm-gear hose clamps or OEM clip-type): old clamps can seize, corrode, or fail.
- Bring your VIN or the old filter to the parts counter to confirm the correct part number; aftermarket brands (Bosch, Denso, Fram) make compatible units but verify fit.

- Tools (every tool described and how to use it)
- Socket set and ratchet (3/8" drive common): used to remove mounting bolts or bracket nuts. Choose the correct socket size and pull the ratchet handle smoothly; avoid rounding bolt heads.
- Combination wrench set (open/box end): useful where sockets can’t reach. Use the correctly sized wrench and pull toward the fixed jaw to reduce slipping.
- Screwdrivers (flat and Phillips): for hose clamps or plastic clips. Use the correct driver width to avoid stripping screw heads.
- Pliers (slip-joint and needle-nose): used to pry off small clips, compress spring clamps, or hold components. Needle-nose helps when working in tight spaces.
- Locking pliers / vice grips: useful to clamp a fuel line or hold a stubborn bolt if needed. Use carefully — fuel lines can be damaged.
- Fuel line quick-disconnect tool(s) (plastic or metal collars set): specific tool(s) that fit Toyota quick-connect fuel fittings to depress the retainer and release the line. How to use: slide the proper-size collar into the female coupling until it seats, then pull the line off the fitting. These are often sold as a small set (multiple diameters). Required because Toyota quick-disconnects lock internally and won’t release reliably with generic pliers.
- Hose clamp pliers or long-nose pliers for spring clamps: compress the spring clamp and slide it back off the filter. Regular pliers can work but clamp pliers make it safer/easier.
- Flat pry tool or panel clip remover: to remove any plastic shields or clips without breaking them.
- Jack and jack stands (or ramps) and wheel chocks: if the filter is under the vehicle, you need to safely lift and support the vehicle. Never rely on a jack alone. Use jack stands rated for your vehicle.
- Drain pan / sealed container and absorbent pads: to catch fuel that drains out when you remove the filter.
- Funnel and small hand pump (optional): to transfer fuel safely if you want to move fuel from one container to another.
- Torque wrench (optional): for reinstalling bracket bolts to proper spec if you want correct torque — hand-tightening is common on filter brackets but follow OEM torque if available.
- Flashlight or headlamp: to see under the vehicle.
- Penetrating oil (e.g., PB Blaster) and wire brush: to free rusty bolts and clean connection points if seized.

- Extra tools that may be required (and why)
- Fuel pump removal tool or large lockring tool (if in-tank module must be removed): the pump module often has a locking ring that requires a special tool or a sturdy spanner/hammer-and-screwdriver technique. Required because the module must be removed from the tank to access the internal filter or replace the pump.
- Fuel tank support strap or transmission jack (if you must drop the tank): needed to safely lower the tank to reach the pump. Required because the tank is heavy, often contains residual fuel, and must be supported while you disconnect lines and electrical connectors.
- Replacement fuel pump module: required only if the in-tank filter is integrated and you cannot service it separately or if pump is failing.

- Step-by-step procedure for an external/serviceable inline filter (typical, concise)
- Relieve fuel pressure: remove the fuel pump fuse/relay and start the engine until it stalls, then crank a couple more seconds to depressurize lines; this reduces fuel spray when lines are opened.
- Disconnect negative battery terminal.
- Safely lift vehicle if filter is underframe; chock wheels and support with jack stands.
- Locate the filter; note arrow marking for flow direction; take a photo for reference.
- Place drain pan under the filter and loosen clamps/band holding filter in bracket.
- Disconnect quick-connect fittings using the proper fuel line disconnect tool: slide tool into the female fitting to release the retaining ring, then pull line straight off. For hose-type connections with spring clamps, compress the clamp and slide off.
- Remove old filter from bracket and wipe up small fuel spills with absorbent rag.
- Compare old and new filter orientation and fittings. Replace any O-rings or quick-connect collars.
- Install new filter with arrow pointing toward engine; reconnect fittings until they click or seat fully.
- Reinstall bracket and tighten bolts/clamps. Replace hose clamps if corroded.
- Reconnect negative battery and reinstall fuel pump fuse/relay.
- Turn key to ON (do not start) for a few seconds to prime system and check for leaks; repeat once or twice, then start engine and inspect for leaks while idling.
- Lower vehicle, test drive briefly, and recheck for leaks. Properly dispose of old filter and fuel-soaked rags.

- If your 4Runner has an in-tank/integrated filter (non-serviceable)
- Expect a more involved job: requires dropping the fuel tank or removing the pump access cover (some models have an access panel under the rear seat — check your model).
- You will likely need the tank support equipment, special pump lockring removal tool, and careful handling of fuel. Electrical connectors and fuel lines to the pump must be disconnected.
- Consider replacing the entire fuel pump module or having a shop perform the work if you do not have the tools/experience. Replacing the module typically includes a new pump and filter sock and ensures proper fit and function.
- If you attempt this yourself, follow the same safety steps, drain the tank to reduce weight/fuel, support the tank securely, and follow a factory service manual procedure for your model year.

- Common pitfalls and tips
- Fuel filters are directional — reversing will starve the engine or cause leaks.
- Use the correct quick-disconnect tool size — forcing the connector will break the plastic and cause leaks.
- Replace any brittle plastic fittings and cracked hoses while you’re in there.
- Never smoke or have open flames nearby; gasoline vapors are extremely flammable.
- If you find heavily corroded bolts or seized fittings, penetrating oil and patience (or replacement fasteners) will avoid breaking things.
- If unsure about in-tank work, get a quote from a shop — labor and special tools are the common reasons to have pros do it.

- Disposal and cleanup
- Seal used fuel and contaminated rags in approved containers or absorbent disposal bags; take to a hazardous waste facility or auto-parts store that accepts used fuel/filters.
- Clean tools with a suitable solvent and ventilate used rags while drying before disposal.

- Final checklist before finishing
- No fuel smell and no visible leaks at new fittings.
- Engine runs smoothly at idle and under light load.
- All brackets and shields reinstalled and fasteners tightened.
- Old parts and fuel safely contained for disposal or recycling.

- Quick part-sourcing advice (do this before you buy)
- Bring the old filter, or your VIN/year/engine code, to the parts counter. Ask for OEM or a recommended aftermarket match.
- If unsure whether your model has an external filter, ask the parts counter or consult a factory service manual for your exact model year.

Done.
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