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Fuel Tank: Installation

NOTE: Always use "Tone" socket wrench E10 when removing the rear seat.
  1. INSTALL FUEL TANK ASSEMBLY 
    1. Install the fuel tank main tube onto the fuel tank.
    2. Clean the bolt hole and remove any grease.
      Fig 1: Identifying Fuel Tank Main Tube
      G04829115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the fuel tank with 4 new bolts.

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

      Fig 2: Locating Fuel Tank Bolts
      G04829114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY LOWER 
    1. Connect the fuel tank filler pipe and install the clamp.
      Fig 3: Locating Fuel Tank Filler Pipe Clamp
      G04829113Courtesy 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 4: Aligning Fuel Tank Breather Tube Connector With Pipe
      G04829119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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 5: Aligning Fuel Tube Connector With Pipe, Push Fuel Tube Connector
      G04829120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the fuel tank protector sub-assembly with the bolt and clip.

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

      Fig 6: Locating Fuel Tank Protector Sub-Assembly Bolt
      G04829110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT FLOOR HEAT INSULATOR NO. 4 
    1. Install the 2 nuts.

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

      Fig 7: Locating Front Floor Heat Insulator No. 4 Nuts
      G04829109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (See  INSTALLATION   ) 
  8. INSTALL FUEL PUMP GAUGE RETAINER (See  INSTALLATION   ) 
  9. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY (See  INSTALLATION   ) 
  10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (See  FUEL TANK   ) 
  11. CONNECT REAR FLOOR SERVICE HOLE COVER (See  FUEL TANK   ) 
  12. INSTALL REAR SEAT ASSEMBLY (for Hatchback) (See  INSTALLATION  ) 
  13. INSTALL REAR SEAT LEG COVER NO. 2 (for Hatchback) (See  INSTALLATION  ) 
  14. INSTALL REAR SEAT LEG COVER NO. 1 (for Hatchback) (See  INSTALLATION  ) 
  15. INSTALL DECK FLOOR BOX (for Hatchback) (See  INSTALLATION  ) 
  16. INSTALL DECK BOARD SUB-ASSEMBLY (for Hatchback) (See  INSTALLATION  ) 
  17. INSTALL PACKAGE TRAY TRIM PANEL ASSEMBLY (for Hatchback) (See  INSTALLATION  ) 
  18. INSTALL REAR SEAT CUSHION COVER PAD (for Sedan) (See  INSTALLATION  ) 
  19. INSTALL REAR SEAT CUSHION COVER PAD (for Hatchback) (See  INSTALLATION  ) 
  20. ADD FUEL 
  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

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

  22. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION   ) 
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