Toyota 77001-21101
Fuel Tank

A proper 2AZ-FE engine fuel tank assembly requires the installation of 10 new fuel tank cushions onto the fuel tank according to the provided illustration. Install the fuel tube clamp through a bolt connection ensuring proper torque reaches 6.0 Nm (60 kgf-cm or 53 in-lbf). The second fuel tube clamp installation requires alignment of the clip positions before adding the tank suction tube support. First position the floor wire's claw points correctly on the fuel tank protector plate before mounting the wire harness clamp and floor wire through three wire harness clamps. Connect the fuel tank vent hose by placing its connector onto the pipe while pushing until the connector reaches the seat then push the retaining clip up until the claws lock together. The user should check that no scratches or foreign material exists near the fuel tube connector connection point and pipes and perform a pull test on the fuel tank vent hose connection to confirm its secure fitment. Place the fuel tank main tube inside both the fuel tube clamp and tank suction tube support at the same time.

The first step in fuel tank disassembly requires removal of the fuel tank main tube from two components which include the fuel tube clamp and tank suction tube support. Before proceeding remove the fuel tank vent hose first by releasing the hose clamp then pinching the tab of the retainer to unlock the lock claws followed by pulling the hose out of the pipe while inspecting for dirt or foreign objects on the hose connector before avoiding any damage to parts. All work should be performed by hand while avoiding any bending, twisting or turning motions of the nylon tube. To protect the disconnected fuel tank vent hose parts wrap them with a plastic bag while performing a gentle push-and-pull technique on fixed hose connector and pipe connections. The fuel tank protector plate can be removed by disconnecting the wire harness clamp first since this step requires two claw fittings to separate and separate the floor wire from the three wire harness clamps. The first task involves removing the tank suction tube support by separating clip fittings followed by separating the two fittings for removing the No. 3 fuel tube clamp. Finish the clamp removal of No. 4 fuel tube with a bolt before fully extracting the ten fuel tank cushions from the tank.

Install ten new fuel tank cushions onto the fuel tank, followed by the No. 4 fuel tube clamp using the bolt, torqued to 6.0 N.m (60 kgf.cm, 53 in.lbf).

Use a transmission jack to hold the fuel tank.

Remove the canister assembly and the rear suspension brace lower LH by removing 3 bolts, followed by the rear suspension brace lower RH by removing 2 bolts.

Add fuel, install the fuel suction with pump & gauge tube assembly, reconnect the battery negative terminal at a torque of 5.4 N.m, and check for fuel and exhaust gas leakage.

First disconnect the fuel tank main tube by pinching the tab of the retainer to remove the lock claws, pushing it down, and pulling the tube out, ensuring no dirt or foreign objects are present and avoiding scratches.