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Fuel Tank: Installation

  1. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect a new fuel tank to filler pipe hose to the fuel tank.

    HINT:

    Make sure that the hose and tank are connected as shown in the illustration.

    Fig 1: Identifying Fuel Tank Location And Filler Pipe Hose Marking
    G04962591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Push in the tube connector to the pipe until the connector makes a "click" sound.
    NOTE:
    • Check if there is any damage or foreign objects on the connected part of the pipe.
    • After connecting, check if the pipe and the connector are securely connected by pulling them.
    Fig 2: Identifying Fuel Tank Breather Tube
    G04962592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY 
    1. Install a new gasket onto the fuel tank.
    2. Set the fuel suction with pump & gage tube assembly to the fuel tank.
      NOTE: Be careful not to bend the arm of the fuel sender gage.
    3. Fit the spline of the fuel suction with pump & gage tube assembly into the keyway of the fuel tank.
      Fig 3: Locating Keyway Of Fuel Tank
      G04962593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the retainer.
      1. Using a new retainer, align the mark on the retainer with the screw-thread starting point of the fuel tank.
      2. While holding the fuel suction with pump & gage tube assembly, tighten the retainer one complete turn by hand.
      Fig 4: Aligning Mark On Retainer With Screw-Thread Starting Point Of Fuel Tank
      G04962594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, tighten the retainer one more complete turn, and position the mark on the retainer into range A of the fuel tank.

      SST 09808-14020 (09808-01410, 09808-01430) 

      HINT:

      • Turn the retainer two complete turns and position the mark within range A to install the retainer.
      • A rib on the retainer can be fitted into the tip of SST.
      Fig 5: Tightening Retainer One More Complete Turn, And Position Mark On Retainer Into Range Of Fuel Tank
      G04962595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Connect the 2 fuel tank tubes with the 2 clips.
    NOTE:
    • Check that there is no scratch or foreign objects on the connecting parts.
    • Check that the connector is fully inserted.
    • Check that the tube joint clip is on the collar of the connector.
    • After installing the tube joint clip, check if the tubes are securely connected by puling then.
    Fig 6: Locating Fuel Tank Tubes With Clips
    G04962596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK CUSHION 
    1. Install 3 new fuel tank cushions to the fuel tank.
  6. INSTALL FUEL TANK ASSEMBLY 
    1. Set a transmission jack to the fuel tank.
    2. Install the fuel tank and 2 fuel tank bands with the 2 bolts.

    Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

    Fig 7: Identifying Fuel Tank Bands
    G04962597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Push in the tube connector to the pipe until the connector makes a "click" sound.
    NOTE:
    • Check that there is no damage or foreign objects on the connected part of the pipe.
    • After connecting, check if the pipe and the connector are securely connected by pulling them.
    Fig 8: Identifying Fuel Tank Breather Tube Connector
    G04962598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Push in the tube connector to the pipe until the connector makes a "click" sound.
    NOTE:
    • Check that there is no damage or foreign objects on the connected part of the pipe.
    • After connecting, check if the pipe and the connector are securely connected by pulling them.
    Fig 9: Identifying Fuel Tank Main Tube And Fuel Tank Return Tube Connector
    G04962599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Set a transmission jack to the fuel tank protector.
    2. Install the fuel tank protector with the 6 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  10. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel filler pipe.

    HINT:

    Make sure that the hose and pipe are connected as shown in the illustration.

    Fig 10: Identifying Hose And Pipe Connection Location
    G04962600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  12. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the connector.
    2. Install the 3 screws and rear floor service hole cover.
    3. Install the rear floor carpet assembly.
  13. INSTALL REAR DOOR SCUFF PLATE LH 
  14. INSTALL QUARTER SCUFF PLATE INSIDE LH 
  15. INSTALL REAR NO. 1 FLOOR STEP COVER 
  16. INSTALL REAR NO. 1 SEAT ASSEMBLY LH 
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