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Fuel Tank: Installation: Installation

  1. INSTALL FUEL TANK CUSHION 
    1. Install 3 new No. 1 fuel tank cushions and 2 new No. 2 fuel tank cushions as shown.
      Fig 1: Identifying No. 1 Fuel Tank Cushion & No. 2 Fuel Tank Cushion
      GTY258926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion
  2. INSTALL FUEL TANK ASSEMBLY 
    1. Support the fuel tank using an engine lifter.
    2. Raise the engine lifter, then install the fuel tank to the vehicle.
      Fig 2: Identifying Support Of Fuel Tank Using An Engine Lifter
      GTY265448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not drop the fuel tank.
      • When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.
    3. Tighten the 4 set bolts of the 2 fuel tank bands.
      Fig 3: Identifying Fuel Tank Bands & Set Bolts
      GTY258887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Connect the parking brake cable assembly with the 2 bolts.
      Fig 4: Identifying Parking Brake Cable Assembly & Bolts
      GTY260451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Push in the fuel tank main tube connector to the pipe and push up the retainer so that the claws engage.
      Fig 5: Identifying Fuel Tank Main Tube Sub-Assembly
      GTY263541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Quick Connector
      *3 Pipe
      *4 O-ring
      *a Push
      NOTE:
      • Check that there are no scratches or foreign objects around the connected parts of the fuel tube connector and pipe before starting this step.
      • After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.
  4. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose to the fuel tank, then fit it with the clamp as shown.
      Fig 6: Identifying Fuel Tank To Filler Pipe Hose
      GTY277503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Upper Side
      *b 120°
  5. CONNECT FUEL TANK BREATHER TUBE 
    1. Push in the fuel tank breather tube connector to the pipe and push up the retainer so that the claws engage.
      Fig 7: Connecting Fuel Tank Breather Tube
      GTY272077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Quick Connector
      *3 Pipe
      *4 O-ring
      *a Push
      NOTE:
      • Check that there are no scratches or foreign objects around the connected parts of the fuel tube connector and pipe before starting this step.
      • After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.
  6. CONNECT FUEL CUT-OFF TUBE 
    1. Push in the fuel cut-off tube connector to the charcoal canister and push up the retainer so that the claws engage.
      Fig 8: Connecting Fuel Cut-Off Tube
      GTY284064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *a Push
      NOTE:
      • Check that there are no scratches or foreign matter around the connected parts of the fuel cut-off tube connector and pipe before performing this work.
      • After connecting the fuel cut-off tube, check that the fuel cut-off tube is securely connected by pulling the fuel cut-off tube connector and the charcoal canister.
  7. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the No. 1 fuel tank protector with the bolt and 2 nuts.
      Fig 9: Identifying No. 1 Fuel Tank Protector, Bolt & Nuts
      GTY282928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  8. INSTALL REAR FLOOR SIDE MEMBER COVER LH  . Refer to INSTALLATION - Step 12
  9. INSTALL REAR FLOOR SIDE MEMBER COVER RH  . Refer to INSTALLATION - Step 13
  10. INSTALL CENTER EXHAUST PIPE ASSEMBLY 
    1. Install the center exhaust pipe assembly. Refer to INSTALLATION .
  11. ADD FUEL 
  12. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Install the fuel suction tube assembly with pump and gauge. Refer to INSTALLATION .
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