Fuel Tank: Installation: Installation

INSTALL FUEL TANK CUSHION
1. Install the 5 tank cushions and fuel tank protector.
  
  Fig 1: Identifying Tank Protector And Tank Cushions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 3 tank cushions.
  
  Fig 2: Identifying Tank Cushions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY

Fig 3: Aligning Fuel Tank Vent Hose Connector With Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the vent hose to the fuel tank.
  1. Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent hose connector until the retainer makes a "click" sound to install the fuel tank vent hose to the fuel tank.
    NOTE:
    Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure.
    
    After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent hose connector.
INSTALL NO. 2 FUEL TANK PROTECTOR

Fig 4: Identifying Fuel Tank Protector Bolt And Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the clamp to the fuel tank.
2. Install the bolt and clip and fuel tank protector to the fuel tank.
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Install the fuel hose clamp.
  
  Fig 5: Locating Fuel Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the fuel tank main tube to the fuel tank with the 6 clamps.
  
  Fig 6: Locating Fuel Tank Main Tube Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Install a new gasket and sender gauge to the fuel tank with the 5 screws.
  
  Fig 7: Locating Fuel Sender Gauge Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
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.
2. Connect the fuel hose, and install the fuel suction with pump and gauge tube.
  
  Fig 8: Locating Fuel Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to bend the arm of the fuel sender gauge.
  - When connecting the fuel hose, do not forcibly pull the hose.
3. Install the lower fuel tank protector and fuel tank vent tube set plate with the 8 bolts.
  
  Fig 9: Locating Fuel Tank Vent Tube Set Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSTALL FUEL TANK ASSEMBLY
1. Set the fuel tank on a transmission jack.
2. Raise the transmission jack so that the fuel tank breather tube can be connected.
  HINT:
  
  Raise the transmission jack slowly.
3. Connect the fuel tank breather tube.
  
  Fig 10: Connecting Fuel Tank Breather Tube Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
4. Connect the fuel vent hose.
  
  Fig 11: Connecting Fuel Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
5. Slowly raise the transmission jack, and install the 2 fuel tank bands with the 4 bolts.
  
  Fig 12: Locating Fuel Tank Bands Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
  NOTE:
  - Do not allow the fuel tank to contact the vehicle, especially the differential.
  - Make sure that the fuel tank is free from the fuel tank vent hose.
6. Connect the filler pipe hose to the fuel tank.
  
  Fig 13: Locating Filler Pipe Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Tighten the clamp.
8. Connect the fuel tank main tube.
  
  Fig 14: Connecting Fuel Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
9. Connect the fuel tank return vent tube.
  
  Fig 15: Connecting Fuel Main Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSTALL FUEL TANK PROTECTOR BRACKET SIDE
1. Install the protector bracket with the 2 bolts.
  
  Fig 16: Locating Protector Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
INSTALL FUEL TANK FILLER PIPE PROTECTOR
1. Attach the 2 clips and protector.
  
  Fig 17: Locating Tank Protector And Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 nuts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
1. Install the propeller with center bearing shaft. Refer to INSTALLATION .
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Install the exhaust pipe. Refer to INSTALLATION .
INSTALL REAR FLOOR SERVICE HOLE COVER

Fig 18: Locating Fuel Sender Gauge Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Connect the fuel sender gauge connector.
2. Install the service hole cover with new butyl tape.
INSTALL FUEL TANK MAIN AND RETURN TUBE

Fig 19: Locating Fuel Tank Return Vent Tube With Tube Joint Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips.
  NOTE:
  Fig 20: Identifying Fuel Tube Joint Correct And Incorrect Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER

Fig 21: Locating Fuel Pump Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Connect the connector.
2. Install the service hole cover with new butyl tape.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSTALL COWL TOP VENTILATOR LOUVER RH . Refer to INSTALLATION - Step 11
PERFORM INITIALIZATION
1. Perform initialization. Refer to INITIALIZATION .
  NOTE:
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSTALL REAR SEAT ASSEMBLY (for Power Seat)
1. Install rear seat assembly. Refer to INSTALLATION .
INSTALL REAR SEAT ASSEMBLY (for Ottoman)
1. Install rear seat assembly. Refer to INSTALLATION .
INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Type)
1. Install rear seat cushion assembly. Refer to INSTALLATION .