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Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK CUSHION 
    1. Install 9 new cushions to the fuel tank.
      Fig 1: Installing 9 Cushions To Fuel Tank
      G04472890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 1 FUEL TUBE CLAMP 
    1. Install the 2 clamps to the fuel tank.
      Fig 2: Installing No. 1 Fuel Tube Clamp
      G04472891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK RETAINER LH 
    1. Install a new gasket to the fuel tank.
    2. While being careful that the gasket does not drop in the fuel tank, insert the fuel tank retainer LH to the fuel tank so the protrusion of the fuel tank retainer LH is in the middle of the 2 convex pats of the fuel tank.
      Fig 3: Installing Gasket To Fuel Tank
      G04472892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK PRESSURE SENSOR 
    1. Push the fuel tank pressure sensor to the plug of the fuel tank retainer LH, and then install the tube joint clip.
      NOTE:
      • Check that there are no scratches or foreign objects around the connected part of the fuel tank pressure sensor and fuel tank retainer LH before this procedure.
      • Check that the fuel tank pressure sensor is securely inserted to the end.
      • Check that the tube joint clip is on the collar of the fuel tank pressure sensor.
      • After installing the tube joint clip, check that the fuel tank pressure sensor cannot be pulled out.
        Fig 4: Installing Fuel Tank Pressure Sensor
        G04472893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL CANISTER 
    1. Install the nut to the fuel tank.
      Fig 5: Installing Fuel Tank Nut
      G04472894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the canister with the bolt and 2 nuts.

      Torque: 6.0 Nm (61 kgf cm, 53 in. lbf) 

    3. Connect the No. 1 canister outlet hose to the fuel tank.
    4. Connect the canister hose to the fuel tank retainer.
      Fig 6: Installing Bolt, Nuts & Hose Clamps
      G04472895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL TANK WIRE 
    1. Install the 3 wire harness clamps as shown in Fig 7 (D).
    2. Connect the vapor pressure sensor connector as shown in Fig 7 (C).
    3. Connect the VSV connector as shown in Fig 7 (B).
    4. Install the clamp as shown in Fig 7 (A).
      Fig 7: Installing Fuel Tank Wire
      G04472896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL TANK VENT HOSE 
    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 trap canister with pump module.
      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.
        Fig 8: Pushing In Fuel Tank Vent Hose Connector
        G04472897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL TRAP CANISTER WITH PUMP MODULE 
    1. Install a new gasket to the fuel tank.
    2. Insert the trap canister with pump module to the fuel tank.
      NOTE: Be careful that the gasket does not drop in the fuel tank.
      Fig 9: Installing Gasket To Fuel Tank
      G04472898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 clamps to the trap canister with pump module.
      Fig 10: Installing Clamps To Trap Canister With Pump Module
      G04472899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the trap canister with pump module and connect the ground terminal of the fuel tank wire with the 2 bolts.

      Torque: 6.0 Nm (61 kgf cm, 53 in. lbf) 

    5. Install the fuel tank vent hose to the 2 fuel tube clamps.
    6. Install the clamp to the fuel tank vent hose and canister hose.
    7. Connect the VSV connector.
      Fig 11: Installing Fuel Tank Vent Hose
      G04472900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL TANK TO CANISTER TUBE 
    1. Install the fuel tank to canister tube to the canister's hose.
    2. Connect the fuel tank to canister tube to the 2 No. 1 fuel tube clamps.
      Fig 12: Installing Fuel Tank To Canister Tube To Canister's Hose
      G04472901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to install the fuel suction tube to the pipe.
      NOTE:
      • Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this procedure.
        Fig 13: Installing Fuel Suction Tube Sub-Assembly
        G04472902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the suction tube connector.
    2. Connect the fuel suction tube to the 2 No. 1 fuel tube clamps.
  11. INSTALL NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Align the main tube connector with the pipe, and then push in the main tube connector until the retainer makes a "click" sound to install the No. 2 fuel tank main tube to the pipe.
      NOTE:
      • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector.
      • After connecting the No. 2 fuel tank main tube, check that the No. 2 fuel tank main tube is securely connected by pulling the main tube connector.
      Fig 14: Pushing In Main Tube Connector
      G04472903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the checker to the pipe.
    3. Connect the No. 2 fuel tank main tube to the clamp.
    4. Connect the connector clamp to the rear fuel tank bracket.
    5. Install the rear fuel tank bracket with the 3 nuts.

      Torque: 6.0 Nm (61 kgf cm, 53 in. lbf) 

      Fig 15: Installing Rear Fuel Tank Bracket With 3 Nuts
      G04472904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank to a transmission jack.
    2. Operate the transmission jack, and then install the fuel tank to the vehicle.
    3. Operate the transmission jack, and then connect the fuel tank inlet pipe.
    4. Install the No. 1 fuel tank band RH and LH with the 4 bolts.

      Torque: 39 Nm (400 kgf cm, 29 ft. lbf) 

    5. Install the fuel tube connector and fuel filler pipe clamp to the fuel tank inlet pipe.
      Fig 16: Installing Fuel Tube Connector And Fuel Filler Pipe Clamp To Fuel Tank Inlet Pipe
      G04472905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the No. 1 canister tube.
      1. Align the No. 1 canister tube connector with the pipe, and then push in the No. 1 canister tube connector until the retainer makes a "click" sound to connect the No. 1 canister tube to the fuel tank to filler pipe.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the No. 1 canister tube connector and pipe before this procedure.
        • After connecting the No. 1 canister tube, check that the No. 1 canister tube is securely connected by pulling the No. 1 canister tube connector.
          Fig 17: Connecting No. 1 Canister Tube
          G04472906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the fuel suction tube.
      1. Align the suction tube connector with the pipe, and then push in the suction tube connector until the retainer makes a "click" sound to connect the fuel suction tube to the fuel tank to filler pipe.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the suction tube connector and pipe before this procedure.
          Fig 18: Connecting Fuel Suction Tube
          G04472907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • After connecting the fuel suction tube, check that the fuel suction tube is securely connected by pulling the suction tube connector.
    8. Connect the fuel tank vent hose.
      1. Align the fuel tank vent hose connector with the pipe, and then push in the fuel tank vent hose connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the canister filter.
        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 vent hose connector.
          Fig 19: Connecting Fuel Tank Vent Hose
          G04472908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the No. 2 fuel tank main tube.
      1. Align the fuel tube connector with the pipe, and then push in the fuel tube connector until the retainer makes a "click" sound to connect the No. 2 fuel tank main tube to the pipe.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before this procedure.
          Fig 20: Connecting No. 2 Fuel Tank Main Tube
          G04472909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • After connecting the No. 2 fuel tank main tube, check that the No. 2 fuel tank main tube is securely connected by pulling the quick connector.
    10. Install the checker to the pipe.
    11. Connect the fuel tank to canister tube.
      1. Align the fuel tank to canister tube connector with the pipe, and then push in the fuel tank to canister tube connector until the retainer makes a "click" sound to connect the fuel tank to canister tube to the pipe.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the fuel tank to canister tube connector and pipe before this procedure.
          Fig 21: Connecting Fuel Tank To Canister Tube
          G04472910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • After connecting the fuel tank to canister tube, check that the fuel tank to canister tube is securely connected by pulling the quick connector.
  13. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See  INSTALLATION  ) 
  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  15. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  16. CHECK FOR EXHAUST GAS LEAKS 
  17. INSTALL FRONT FLOOR PANEL BRACE (See  INSTALLATION  ) 
  18. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See  INSTALLATION  ) 
  19. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Attach new butyl tape to the rear floor service hole cover.
    2. Connect the wire to wire connector.
    3. Connect the fuel pump connector.
    4. Install the rear floor service hole cover while adjusting it to the 3 convex parts of the floor panel.
      NOTE: Be careful that the rear floor service hole cover does not overlap the convex parts of the floor panel when installing.
      Fig 22: Installing Rear Floor Service Hole Cover
      G04472911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL REAR SEAT CUSHION ASSEMBLY (see  INSTALLATION  ) 
  21. 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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