Fuel Tank: Installation

1. Install the fuel tank cushion sets and No. 5 fuel tank cushions.
   Fig 1: Identifying Fuel Tank Cushion Sets & No. 5 Fuel Tank Cushions

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1. Install the fuel tank side plate and the fuel tank bracket with the bolt and nut.

   Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   Fig 2: Identifying Fuel Tank Side Plate & Fuel Tank Bracket

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1. Install a new tank suction tube support.
   Fig 3: Identifying Tank Suction Tube Support

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1. Install a new tank suction tube support and new gasket.
   Fig 4: Identifying Retainer & Gasket

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2. Attach the fuel tank over fill check valve assembly to the fuel tank.
3. Align the keyway of the fuel suction tube support with the key of the fuel tank over fill check valve assembly.
   Fig 5: Aligning Keyway Of Fuel Suction Tube Support With Key

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4. Align the triangle mark on the new fuel pump gauge retainer with the "S" mark, and attach the fuel pump gauge retainer.
   Fig 6: Identifying Triangle Mark On Fuel Pump Gauge Retainer (1 Of 2)

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5. Rotate the fuel pump gauge retainer by hand, then tighten it one complete turn and another half turn using SST.

   The triangle mark on the fuel pump gauge retainer must be positioned between the "MIN" and "MAX" marks on the fuel tank.

   SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

   Fig 7: Identifying Triangle Mark On Fuel Pump Gauge Retainer (2 Of 2)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Do not use other tools in this operation. Damage to the fuel pump gauge retainer and the fuel tank may result.

   HINT:

   A rib on the fuel pump gauge retainer can be fitted into a tip of the SST.

1. Connect the No. 1 evaporation vent tube.
   Fig 8: Identifying No. 1 Evaporation Vent Tube

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   1. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a click sound. If the connection is too tight, apply a small amount of fresh engine oil to the tip of the pipe.
      NOTE:

      • Check for damage or foreign objects on the parts that are to be connected.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
2. Connect the fuel tank vent hose.
   1. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a click sound. If the connection is too tight, apply a small amount of fresh engine oil to the tip of the pipe.
      NOTE:

      • Check for damage or foreign objects on the parts that are to be connected.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 9: Connecting Fuel Tank Vent Hose

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the fuel tank vent hose, and fasten the claw.

Fig 10: Identifying Hose Clamp Bolt

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1. Install the fuel tank to filler pipe hose with the hose clamp.

1. Install the fuel pump tube, and fasten the 2 claws.
   Fig 11: Identifying Fuel Pump Tube Claws

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1. Set up the fuel tank to the transmission jack.
2. Operating the transmission jack, install the fuel tank.
3. Tighten the 2 nuts.

   Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

   Fig 12: Identifying Fuel Tank Mounting Bolts

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4. Install the 2 fuel tank bands with the 4 bolts.

   Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

5. Connect the fuel tank to filler pipe hose.
   Fig 13: Connecting Fuel Tank To Filler Pipe Hose

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6. Connect the No. 3 fuel tank breather tube.
   1. Push the quick connector to the pipe until it makes a "click" sound.
      NOTE:

      • Check if there is any damage or foreign objects on the connected part.
      • After connecting, check if the quick connector and the pipe are securely connected by pulling on them.
      Fig 14: Connecting Fuel Tank Breather Tube No. 3

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the fuel tank vent hose.
8. Connect the fuel pump tube.
   Fig 15: Connecting Fuel Pump Tube

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   1. Push the quick connector and push up the retainer to lock the claws.
      NOTE:

      • Check if there is any damage or foreign objects on the connected part.
      • After connecting, check if the quick connector and the pipe are securely connected by pulling on them.

1. Install the No. 1 fuel tank protector with the 6 nuts.

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

   Fig 16: Identifying Fuel Tank Protector Sub-Assembly No. 1

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2. Install 3 new clips. (A)

1. Install the No. 1 fuel tank protector with the 4 nuts.

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

   Fig 17: Identifying No. 1 Fuel Tank Protector

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Fig 18: Identifying No. 1 Fuel Tube Protector

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1. Install the No. 1 fuel tube protector with the 2 clips and claw.

1. Install the No. 4 exhaust pipe support bracket with the 2 bolts.

   Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

   Fig 19: Identifying Exhaust Pipe Support Bracket No. 4 Bolts

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HINT:

See INSTALLATION .

HINT:

See INSPECTION  .

HINT:

See INSTALLATION .

HINT:

See INSTALLATION .