Fuel Tank: Installation

1. Install the fuel tank main tube sub-assembly onto the fuel tank.
   Fig 1: Identifying & Installing Fuel Tank Main Tube Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new No. 1 fuel tank cushion and 3 No. 2 fuel tank cushion as shown in the illustration.

Fig 2: Identifying & Installing No. 1 & 3 No. 2 Fuel Tank Cushion

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Support the fuel tank using an mission jack.
2. Temporary install the fuel tank with 4 new bolts.
3. Tighten the 4 bolts in the order shown in the illustration.

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

   Fig 3: Locating Fuel Tank With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the parking brake cable assembly with the 2 bolts.

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

   Fig 4: Locating & Connecting 2 Parking Brake Cable Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the fuel tube connector with the pipe, push the fuel tube connector in until the retainer makes a click sound, then lock the connector cover.
   NOTE:

   • Check that there are no scratches or foreign matter on the disconnected parts of the fuel tube connector and pipe before performing this work.
   • After connecting, pull the pipe and fuel tube connector to make sure that they are securely connected.
     Fig 5: Pushing Fuel Tube Connector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the fuel tube connector with the pipe, push the fuel tube connector in until the retainer makes a click sound, then lock the connector cover.
   NOTE:

   • Check that there are no scratches or foreign matter on the disconnected parts of the fuel tube connector and pipe before performing this work.
   • After connecting, pull the pipe and fuel tube connector to make sure that they are securely connected.
     Fig 6: Pulling Pipe And Fuel Tube Connector

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the fuel tank to filler pipe hose with the clamp.
2. Tighten the clamp bolt.
   Fig 7: Locating Clamp Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 1 fuel tank protector sub-assembly with the 3 bolts and nut.

   HINT:

   Tighten the bolts and nut in the order shown in the illustration.

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

   Fig 8: Locating Fuel Tank Protector Sub-Assembly With Bolts And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using vernier calipers, measure the free length of the compression springs. Minimum length: 38.5 mm (1.516 in.)

   If the length is not as specified, replace the compression spring.

   Fig 9: Measuring Free Length Of Compression Springs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold and center exhaust pipe assembly.
   NOTE:

   • Install the exhaust pipe gasket in the correct direction.
   • Do not damage the outer surface of the exhaust pipe gasket.
   • Do not reuse the exhaust pipe gasket.
   • Do not push in the gasket with the exhaust pipe when connecting it.
     Fig 10: Identifying Wooden Block And Gasket

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the new exhaust pipe gasket onto the No. 2 exhaust pipe gasket.
4. Install the No. 2 center exhaust pipe assembly with the 4 bolts and 2 compression spring.
   Fig 11: Locating Center Exhaust Pipe Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rear floor side member brace sub-assembly with the 4 bolts.

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

   Fig 12: Locating Rear Floor Side Member Brace Sub-Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rear floor side member cover LH with the nut, grommet and 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Fig 13: Identifying Rear Floor Side Member Cover LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the rear floor side member cover RH with the nut, grommet and 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

(See FUEL SYSTEM  )