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Fuel Tank: Installation

  1. INSTALL FUEL TANK ASSEMBLY 
    1. Install the fuel vent hose onto the fuel tank.
      2. Fig 1: Identifying Fuel Vent Hose Of Fuel Tank
      G05399503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tank main tube onto the fuel tank.
    3. Clean the bolt hole and remove any grease.
      Fig 2: Identifying Fuel Tank Main Tube
      G04829115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the fuel tank with 4 new bolts.

      Torque: 14 N*m (146 kgf*cm, 10 ft.*lbf) 

      Fig 3: Locating Fuel Tank Bolts
      G04829114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT LOWER FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Connect the fuel tank filler pipe and install the clamp.
      Fig 4: Connecting Fuel Tank Filler Pipe And Clamp
      G05399500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT FUEL TANK BREATHER TUBE 
    1. Align the fuel tank breather tube connector with the pipe, push the fuel tube connector in until the retainer makes a click sound, then lock the cover of the connector.
      NOTE:
      • Check that there are no scratches or foreign matter on the disconnected parts of the fuel tank breather tube connector and pipe before performing this work.
      • After connecting, pull the pipe and fuel tank breather connector to make sure that they are securely connected.
        • Fig 5: Connecting Fuel Tank Breather Tube
        G05399508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT FUEL TANK VENT HOSE 
    1. Connect the fuel tank vent hose to the charcoal canister assembly.
      Fig 6: Connecting Fuel Tank Vent Hose To Charcoal Canister Assembly
      G05399498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    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 cover of the connector.
      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 7: Connecting Fuel Tank Main Tube Sub-Assembly
        G05399510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the No. 1 fuel tank protector with the bolt and clip.

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

      Fig 8: Locating No. 1 Fuel Tank Protector With Bolt And Clip
      G04829110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 4 FRONT FLOOR HEAT INSULATOR 
    1. Install the No. 4 front floor heat insulator with the 2 nuts.

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

      Fig 9: Locating No. 4 Front Floor Heat Insulator With Nuts
      G04829109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  (See INSTALLATION  )
  9. INSTALL FUEL PUMP GAUGE RETAINER  (See INSTALLATION  )
  10. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY  (See INSTALLATION  )
  11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY  (See INSTALLATION  )
  12. CONNECT REAR FLOOR SERVICE HOLE COVER  (See INSTALLATION  )
  13. INSTALL REAR SEAT CUSHION WITH COVER PAD SUB-ASSEMBLY LH  (See INSTALLATION )
  14. INSTALL NO. 2 SEAT LEG COVER  (See INSTALLATION )
  15. INSTALL NO. 1 SEAT LEG COVER  (See INSTALLATION )
  16. ADD FUEL 
  17. INSPECT FOR FUEL LEAK  (See FUEL SYSTEM  )
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