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Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR 
    1. Install the No. 1 fuel tank heat insulator with the 4 clips.
    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.
      Fig 1: Installing Fuel Tank Heat Insulator
      G05628908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel tank as shown in the illustration.

      HINT:

      • Align the fuel tank side mark with the hose side mark when installing the hose.
        Fig 2: Identifying Fuel Tank Mark Location
        G05628909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See INSTALLATION  )
    Fig 3: Identifying Stopper
    G05628910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY 
    1. Install the 2 fuel tank tubes and No. 1 fuel tube joint with the 3 tube joint clips.
      Fig 4: Installing Tube Joint Clips
      G05628913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting parts.
      • Check that the fuel tube joints are 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 5: Identifying Proper Position Of Fuel Tube Joints
        G05628914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tank main tube and fuel tank return tube to the fuel tank.
  5. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set the fuel tank on a transmission jack and raise the fuel tank.
    2. Raise the transmission jack.
      Fig 6: Locating Fuel Main Tube And Fuel Return Tube
      G05628904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 fuel tank bands with the 2 pins and 2 clips.
    4. Connect the 2 fuel tank bands with the 2 bolts.

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

      Fig 7: Locating Fuel Tank Bands Bolts
      G05628902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose to the fuel tank filler pipe as shown in the illustration.

      HINT:

      • Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.
        Fig 8: Locating Fuel Tank To Filler Pipe Hose
        G05759634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
        Fig 9: Identifying Stopper
        G05628910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank breather tube to the fuel tank filler pipe.

      HINT:

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 10: Connecting Fuel Tank Breather Tube To Fuel Tank Filler Pipe
        G05759636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the fuel tube clamp.
  8. CONNECT NO. 2 FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank breather tube to the filler pipe and push the retainer.
      NOTE:
      • Before installing the hose, make sure that it is not damaged. Make sure that there is no foreign matter present on the connecting surfaces.
      • After connecting, check if the hose and the connector are securely connected by pulling on them.
    2. Attach the 2 fuel tube clamps.
      Fig 11: Connecting Fuel Tank Breather Tube To Filler Pipe And Pushing Retainer
      G05759637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank return tube and push the retainer.

      HINT:

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
      Fig 12: Connecting Fuel Tank Return Tube And Pushing Retainer
      G05628921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube and push the retainer.

      HINT:

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
      Fig 13: Connecting Fuel Tank Main Tube And Pushing Retainer
      G05628922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the tank protector with the 5 bolts.

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

  12. INSTALL FUEL TANK CAP ASSEMBLY 
    Fig 14: Locating Fuel Tank Protector Bolts
    G05628891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Connect the fuel pump and fuel sender gauge connector.
      Fig 15: Locating Fuel Pump And Fuel Sender Gauge Connector
      G05628897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the service hole cover with new butyl tape.
      Fig 16: Identifying Service Hole Cover
      G05628896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the air duct with the 2 screws.
  14. INSTALL FRONT FLOOR CARPET ASSEMBLY  (See INSTALLATION )
  15. INSTALL REAR SEAT ASSEMBLY 
    1. Install the rear No. 1 seat assembly and rear No. 2 seat assembly (See INSTALLATION ).
  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
    Fig 17: Locating Air Duct Screws
    G05628895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. ADD FUEL 
  18. INSPECT FOR FUEL LEAK  (See INSTALLATION  )
  19. INSPECT REAR NO. 1 SEAT ASSEMBLY RH  (See INSTALLATION )
  20. INSPECT REAR NO. 1 SEAT ASSEMBLY LH  (See INSTALLATION )
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