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Fuel Tank: Installation: Installation

  1. INSTALL FUEL TANK CUSHION 
    1. Install new fuel tank cushions onto the fuel tank.
      Fig 1: Identifying Fuel Tank Cushions
      GTY194651Courtesy 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 Tank Clamp
      GTY177606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Install the fuel tank main tube onto the fuel tank.
      Fig 3: Locating Fuel Tank Main Tube
      GTY177631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank on a transmission jack.
    2. Operate the transmission jack, then install the fuel tank into the vehicle.
      Fig 4: Holding Fuel Tank With Transmission Jack
      GTY188416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 No. 1 fuel tank bands with the 4 bolts.

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

  5. INSTALL FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Connect the fuel tank filler pipe to the fuel tank.
      Fig 5: Connecting Fuel Tank To Filler Pipe Hose To Fuel Tank
      GTY172365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the hose clamp is facing the correct direction when installing.

    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
      GTY174222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube.
      Fig 7: Connecting Fuel Tank Main Tube
      GTY185850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  7. CONNECT BREATHER TUBE FUEL HOSE 
    1. Connect the breather tube fuel hose.
      Fig 8: Locating Breather Tube Fuel Hose
      GTY172593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the breather tube fuel hose.
      Fig 9: Connecting Breather Tube Fuel Hose
      GTY232521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  8. CONNECT FUEL TANK VENT HOSE 
    1. Connect the fuel tank vent hose.
      Fig 10: Connecting Fuel Tube Connector (Quick Type C)
      GTY227463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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  . Refer to INSTALLATION - Step 1
  10. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the fuel tank protector sub-assembly with the 4 bolts.
      Fig 11: Identifying No. 1 Fuel Tank Protector With Bolts
      GTY184503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  11. CONNECT PARKING BRAKE CABLE 
    1. Install the parking brake cables with the 4 bolts.
      Fig 12: Locating Parking Brake Cables Bolts
      GTY194652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT EXHAUST PIPE ASSEMBLY  . Refer to INSTALLATION - Step 4
  13. ADD FUEL 
  14. INSTALL FUEL SENDER GAUGE ASSEMBLY  See step  1
  15. INSTALL FUEL SUCTION TUBE ASSEMBLY 
    1. Install the fuel suction tube assembly to the fuel tank assembly. Refer to INSTALLATION .
  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  17. INSPECT FOR FUEL LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  18. INSPECT FOR EXHAUST GAS LEAK 
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