Fuel Tank: Installation: 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 cushions 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.
   Fig 3: Identifying Fuel Tank Assembly Bolt Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten the 4 bolts in the order shown in the illustration.

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

4. Connect the parking brake cable assembly with the 2 bolts.
   Fig 4: Identifying Parking Brake Cable Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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.
   Fig 5: Pushing Fuel Tube Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

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.
   Fig 6: Pulling Pipe And Fuel Tube Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the clamp bolt.

1. Install the No. 1 fuel tank protector sub-assembly with the 3 bolts and nut.
   Fig 8: Locating Fuel Tank Protector Sub-Assembly With Bolts And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

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

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

1. Using a vernier caliper, measure the free length of the compression springs.
   Fig 9: Measuring Free Length Of Compression Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Minimum length

   38.5 mm (1.516 in.)

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

2. Fully push a new exhaust pipe gasket onto the 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.
3. Install the new exhaust pipe gasket onto the No. 2 center exhaust pipe assembly.
4. Hang the No. 2 center exhaust pipe assembly with the No. 4 exhaust pipe support.
   Fig 10: Locating Center Exhaust Pipe Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the No. 2 center exhaust pipe assembly with the 4 bolts and 2 compression springs.

   Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

1. Install the rear floor side member cover LH with the nut, grommet and 2 bolts.
   Fig 11: Identifying Rear Floor Side Member Cover LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Install the rear floor side member cover RH with the nut, grommet and 2 bolts.
   Fig 12: Locating Rear Floor Side Member Cover RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Refer to INSTALLATION

Refer to INSTALLATION