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Fuel Tank: Installation

  1. INSTALL FUEL TANK CUSHION 
    1. Install the tank cushion and tank protector.
      Fig 1: Identifying Tank Cushion And Tank Protector
      G05303311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 11 tank cushions.
    Fig 2: Identifying Fuel Tank Cushions
    G05303310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Install the vent hose to the fuel tank.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      Fig 3: Installing Vent Hose To Fuel Tank
      G05303314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Attach the 2 claws to the claw holes and install a new edge protector.
      Fig 4: Attaching Claws To Claw Holes
      G05303315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clamp, fuel tank main tube and return tube.
    Fig 5: Locating Clamp, Fuel Tank Main Tube And Return Tube
    G05303307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Install a new gasket and the canister tube with the 4 screws.

      Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

      Fig 6: Locating Canister Tube And Screws
      G05303306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK WIRE 
    1. Install the tank wire with the 7 clamps.
      2. Fig 7: Locating Clamps And Tank Wire From Tank
      G05303305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FUEL TANK VENT TUBE SET PLATE  (See REMOVAL )
  7. INSTALL FUEL TANK PRESSURE SENSOR  (See INSTALLATION )
  8. INSTALL NO. 3 FUEL TANK PROTECTOR  (See INSTALLATION )
  9. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set the fuel tank on a mission jack and raise the fuel tank.
    2. Install the clamp, and connect the fuel filler pipe to the fuel tank.
      Fig 8: Installing Clamp
      G05814400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Insert the filler pipe into the fuel tank with their axes aligned. If not aligned, the insertion load increases.
      • Do not twist or forcefully insert the filler pipe.
      • After securely inserting the filler pipe into the fuel tank, attach the clamp. At this time securely insert the clamp into the slit.
        • Fig 9: Inserting Filler Pipe Into Fuel Tank
        G05303320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Raise the mission jack.
    4. Install the 2 fuel tank bands with the 4 bolts.

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

      Fig 10: Locating Fuel Tank Bands With Bolts
      G05303303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the 2 fuel filler pipe bolts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Fig 11: Locating Fuel Filler Pipe Bolts
      G05303302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT FUEL TANK WIRE 
    1. Connect the fuel vapor containment valve connector and 2 clamps.
    Fig 12: Locating Fuel Vapor Containment Valve Connector And Clamps
    G05303301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY 
    1. Connect the canister tube and install the clamp.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      Fig 13: Connecting Fuel Tank To Canister Tube Sub-Assembly
      G05303324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Connect the fuel tank vent hose and install the clamp.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      Fig 14: Locating Fuel Tank Vent Hose
      G05303325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube (LH).

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      Fig 15: Connecting Fuel Tank Main Tube (LH)
      G05303326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the fuel tank main tube (RH).

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      Fig 16: Connecting Fuel Tank Main Tube (RH)
      G05303327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT FUEL TANK RETURN VENT TUBE 
    1. Connect the fuel return vent tube and install the retainer.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      Fig 17: Connecting Fuel Return Vent Tube
      G05303328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Connect the 2 parking brake cables to the parking brake equalizer.
    2. Install the 2 parking brake cables with the 4 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) for bolt A 

      19 N*m (193 kgf*cm, 14 ft.*lbf) for bolt B 

    3. Attach the 2 parking brake cables to the 4 clamps.
    Fig 18: Locating Parking Brake Cables With Bolts
    G05303329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR SUSPENSION MEMBER BRACE RH 
    1. Install the suspension member brace with the 4 bolts.

      Torque: 19 N*m (193 kgf*cm, 14 ft.*lbf) 

      Fig 19: Locating Suspension Member Brace Bolts
      G05303294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL REAR SUSPENSION MEMBER BRACE LH 
    1. Install the suspension member brace with the 4 bolts.

      Torque: 19 N*m (193 kgf*cm, 14 ft.*lbf) 

      Fig 20: Locating Suspension Member Brace Bolts
      G05303293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REAR FLOOR SIDE MEMBER COVER LH 
    1. Install the member cover with the 3 bolts.
    Fig 21: Locating Member Cover Bolts
    G05303291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR FLOOR SIDE MEMBER COVER RH 
    1. Install the member cover with the 3 bolts.
    Fig 22: Locating Member Cover With Bolts
    G05303292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Install the differential supporter with the 2 nuts.
  21. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Install the differential supporter with the 2 nuts.
    Fig 23: Locating Differential Support Protector Nuts
    G05287075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY  (See INSTALLATION )
  23. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY  (See INSTALLATION )
  24. ADJUST NO. 2 AND NO. 3 JOINT ANGLE  (See INSTALLATION )
  25. INSTALL OUTSIDE AIR GUIDE PLATE RH 
    1. Install the plate with the 4 nuts.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 24: Locating Outside Air Guide Plate Nuts
      G05295991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR 
    1. Install the heat insulator with the 5 nuts.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 25: Locating Heat Insulator Nuts
      G05303288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FRONT FLOOR COVER CENTER LH 
    1. Install the floor cover center with the 3 nuts.
    Fig 26: Locating Floor Cover Center With Nuts
    G05303287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL FRONT FLOOR COVER CENTER RH 
    1. Install the floor cover center with the 3 nuts.
      2. Fig 27: Locating Floor Cover Center With Nuts
      G05814419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL EXHAUST PIPE ASSEMBLY 
    1. Install the exhaust pipe (see INSTALLATION ).
  30. INSTALL FUEL SENDER GAUGE ASSEMBLY 
    1. Install the sender gauge with the 5 screws.

      Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

      Fig 28: Locating Fuel Sender Gauge Screws
      G05303285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel sender gauge connector.
    2. Install the service hole cover with new butyl tape.
  32. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
      Fig 29: Locating Service Hole Cover And Fuel Sender Gauge Connector
      G05303284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the fuel hose, and set the fuel suction with pump and gauge.
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • When connecting the fuel hose, do not forcibly pull the hose.
      Fig 30: Locating Fuel Hose
      G05303283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the set plate with the 8 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      HINT:

      Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.

      Fig 31: Locating Set Plate With Bolts
      G05303342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 fuel tank tubes with the 2 tube joint clips.
    Fig 32: Identifying Fuel Tank Tubes With Tube Joint Clips
    G05303343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • Check that there are no scratches or foreign objects on the connecting parts.
    • Check that the fuel tube joint is inserted securely.
    • Check that the tube joint clips are on the collars of the fuel tube joints.
    • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
    Fig 33: Installing Tube Joints Clips
    G05303344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Connect the 2 connectors.
    2. Install the service hole cover with new butyl tape.
    Fig 34: Locating Service Hole Cover And Connectors
    G05303280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL ROOM NO. 3 PARTITION PAD 
    1. Install the partition pad with the clip.
      2. Fig 35: Identifying Room Partition Pad With Clip
      G05287239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL REAR SEAT CUSHION ASSEMBLY  (See INSTALLATION )
  36. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  38. CHECK FOR FUEL LEAKS  (See ON-VEHICLE INSPECTION )
  39. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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