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Fuel Tank: Reassembly

  1. INSTALL NO. 1 FUEL TANK CUSHION 
    1. Install 10 new fuel tank cushions onto the fuel tank as shown in the illustration.
      Fig 1: Identifying Fuel Tank Cushions On Fuel Tank
      G05538520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 4 FUEL TUBE CLAMP 
    1. Install the fuel tube clamp with the bolt.

      Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf) 

      Fig 2: Locating Fuel Tube Clamp With Bolt
      G05538519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 3 FUEL TUBE CLAMP 
    1. Align the clip positions, then install the fuel tube clamp.
      Fig 3: Identifying No. 3 Fuel Tube Clamp
      G05538523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TANK SUCTION TUBE SUPPORT 
    1. Align the clip position, then install the tank suction tube support.
      Fig 4: Locating Clip Fittings And Tank Suction Tube Support
      G05538524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 3 FLOOR WIRE 
    1. Align the claws positions, then install the fuel tank protector plate.
    2. Install the wire harness clamp.
      Fig 5: Locating Wire Harness Clamp
      G05538516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the floor wire with the 3 wire harness clamps.
      Fig 6: Locating Floor Wire With Wire Harness Clamps
      G05538515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL TANK VENT HOSE 
    1. Align the hose connector with the pipe, then push in the hose connector until it comes into contact with the seat to connect the fuel tank vent hose to the pipe. Then push the retainer up until to the claws lock.
      Fig 7: Locating Hose Connector With Pipe
      G05538527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hose into the hose clamp.
      NOTE:
      • Check that there are no scratches or foreign objects around the connected part 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 the hose connector and pipe.
  7. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Fit the fuel tank main tube into the fuel tube clamp and tank suction tube support.
      Fig 8: Locating Fuel Tank Main Tube And Tank Suction Tube Support
      G05538513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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