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Fuel Tank: Installation

  1. INSTALL FUEL TANK CUSHION 
    1. Install new fuel tank cushions onto the fuel tank.
      Fig 1: Identifying Fuel Tank Cushions
      G06009808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK VENT HOSE 
    1. Install the fuel tank vent hose onto the fuel tube clamp.
      Fig 2: Locating Fuel Tube Clamp
      G05193300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Install the fuel tank main tube onto the fuel tank.
  4. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank on a transmission jack.
      Fig 3: Locating Fuel Tank Main Tube
      G05193299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Operate the transmission jack, then install the fuel tank into the vehicle.
    3. Install the 2 No. 1 fuel tank bands with the 4 bolts.

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

      Fig 4: Installing Fuel Tank Into Vehicle
      G06009804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Connect the fuel tank filler pipe to the fuel tank.
      NOTE: Make sure that the hose clamp is facing the correct direction when installing.
      Fig 5: Connecting Fuel Tank Filler Pipe To Fuel Tank
      G05193306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
      Fig 6: Identifying Fuel Tank Filler Pipe Cover Claw
      G06009938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
        NOTE:
        • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
        • After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.
        Fig 7: Connecting Fuel Tank Main Tube
        G06009951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT BREATHER TUBE FUEL HOSE 
    1. Connect the breather tube fuel hose.
      Fig 8: Locating Breather Tube Fuel Hose
      G06009800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the breather tube fuel hose.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
        NOTE:
        • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
        • After connecting the fuel tank breather tube, check that the fuel pump tube is securely connected by pulling on the fuel tube connector and pipe.
      2. Install the checker onto the pipe.
        Fig 9: Connecting Breather Tube Fuel Hose
        G06041970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT FUEL TANK VENT HOSE 
    1. Connect the fuel tank vent hose.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
      2. Slide the retainer of the fuel tube connector to lock the claws as shown in the illustration.
        NOTE:
        • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
        • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tube connector.
  9. INSTALL CHARCOAL CANISTER ASSEMBLY  (See INSTALLATION )
    Fig 10: Connecting Fuel Tank Vent Hose
    G06041812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the fuel tank protector sub-assembly with the 4 bolts.

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

      Fig 11: Locating Fuel Tank Protector Sub-Assembly Bolts
      G06009797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT PARKING BRAKE CABLE 
    1. Install the parking brake cables with the 4 bolts.
  12. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  13. ADD FUEL 
  14. INSTALL FUEL SENDER GAUGE SUB-ASSEMBLY  (See INSTALLATION )
    Fig 12: Locating Parking Brake Cables Bolts
    G06009796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FUEL SUCTION TUBE ASSEMBLY 
    1. Install the fuel suction tube assembly to the fuel tank assembly (See INSTALLATION  ).
  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  17. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  18. INSPECT FOR EXHAUST GAS LEAK 
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