Toyota 77001-04201
Fuel Tank

The installation process for the 2TR-FE fuel tank begins with attaching the No. 1 fuel tank protector through 4 clips. You must attach the fuel tank to the filler pipe hose while securing it with proper pipe clamp bolt tightening. Set the fuel pump assembly into the tank with the arm of the sender gauge free of any bends before installing a fresh gasket on the fuel tank. Insert the spline portion of the fuel suction tube assembly in the keyway of the fuel tank before installing a new retainer which should align its mark with the tank rib while you use tool 09808-01410 to torque the retainer to 740-780 degrees range A. Following the setup of Special Service Tool: 09808-14020 09808-01410 rotate the retainer 740 degrees to 780 degrees clockwise to place the mark inside range A. After that install both fuel tank tubes using the two joint clips while inspecting for any scratches or foreign elements around the attached parts and confirming correct clip positioning. Place the fuel tank assembly on the mission jack while you secure the fuel tank vent hose through connecting its connector with the pipe until it clicks into place then verify all connections are tight. Secure the fuel pump connector followed by attachment of the fuel tank to filler pipe hose which is then covered by the fuel pump cover. Fasten the 2 fuel tank bands to the 2 pins and 2 clips and 2 bolts while torquing them to 62 Nm (632 kgf-cm, 46 ft-lbf). The fuel tank breather tube needs to be attached while its locking mechanism clicks into position then you should install a checker onto the pipe before applying torque to the clamp bolt. Thoroughly connect the main tubes and return tubes of the fuel tank where they lock into position to become secure. Connect the negative battery cable by first adding fuel before installation of the clamp and torquing the cable screw to 3.9 Nm (40 kgf-cm, 35 in-lbf). Finally, check for fuel leaks.

The process begins with attaching the No. 1 fuel tank protector to its places using four clips. Apply the fuel tank to the filler pipe hose before you tighten the pipe clamp bolt. We should apply a new gasket on the fuel tank before setting the fuel pump assembly inside while making sure the gauge sender arm stays undamaged. Air the spline of the fuel suction tube assembly into keyway position of the fuel tank before attaching a new retainer while positioning its mark on the fuel tank rib. The retainer 740 degrees should be turned clockwise using Service Tool 09808-14020 09808-01410 up to a maximum of 780 degrees to reach range A. After this, install the main tube and return tube with their 2 joint clips by checking that nearby parts have no scratches or foreign materials present before securely fastening the clips. Set the mission jack under the fuel tank assembly while connecting the fuel tank vent hose by inserting its connector into the pipe until it clicks and fitting the fuel pump connector with the filler pipe hose. The installation of fuel pump cover, two fuel tank bands requires two pins, two clips and two bolts while torque settings reach 62 Nm (632 kgf-cm, 46 ft-lbf). The breather tube should be attached securely until it clicks before installing the pipe checker followed by bolt clamp tightening. Install the fuel pipe clamp after connecting both the fuel tank main tube and return tube which fit into position securely. A fuel mixture should be added before connecting a cable to the negative terminal with a torque setting of 3.9 Nm (40 kgf-cm, 35 in-lbf) while inspecting for fuel leakages.

Loosen the clamp bolt.

Remove the gasket and drain the fuel.

Disconnect the fuel pump connector and the fuel tank vent hose by pinching the retainer and pulling the connector out of the charcoal canister.

Install the fuel pump cover and the two fuel tank bands, tightening them to a torque of 62 N.m.