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Fuel Tank: Installation: Installation

  1. INSTALL FUEL TANK COVER VENT CASE SUB-ASSEMBLY 
    1. Install 2 new fuel tank cover vent case sub-assemblies as shown in the illustration.
      Fig 1: Identifying Fuel Tank Cover Vent Case Sub-Assembly
      GTY291112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 1 FUEL TANK CUSHION 
    1. Install 3 new No. 1 fuel tank cushions as shown in the illustration.
      Fig 2: Identifying No. 1 Fuel Tank Cushion
      GTY292177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Fuel Tank Cushion
  3. INSTALL FUEL TANK ASSEMBLY 
    1. Support the fuel tank using an engine lifter.
    2. Raise the engine lifter, then install the fuel tank to the vehicle.
      Fig 3: View Of Supporting Fuel Tank With An Engine Lift
      GTY223847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not drop the fuel tank.
      • When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.
    3. Tighten the 4 set bolts of the 2 fuel tank bands.
      Fig 4: Identifying Fuel Tank Banks & Set Bolts
      GTY224676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

    4. Connect the parking brake cable assembly with the 2 bolts.
      Fig 5: Identifying Parking Brake Cable Assembly Bolts
      GTY223670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Push in the fuel tank main tube connector to the pipe and push up the retainer so that the claws engage.
      Fig 6: Identifying Fuel Tank Main Tube Connector
      GTY217976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Quick Connector
      *3 Pipe
      *4 O-ring
      NOTE:
      • Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and pipe before starting this step.
      • After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.
  5. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Push in the hose connector to the filler pipe and install the retainer.
      Fig 7: Identifying Fuel Tank To Filler Pipe Hose
      GTY212726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      NOTE:
      • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt or foreign matter present on the connecting surfaces.
      • After connecting, check if the fuel tube connector and the pipe are securely connected by pulling on them.
  6. CONNECT FUEL TANK BREATHER TUBE 
    1. Push in the fuel tank breather tube connector to the pipe and push up the retainer so that the claws engage.
      Fig 8: Identifying Fuel Tank Breather Tube
      GTY223367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 Quick Connector
      *3 Pipe
      *4 O-ring
      NOTE:
      • Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and pipe before starting this step.
      • After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.
  7. CONNECT FUEL CUT-OFF TUBE 
    1. Push in the fuel cut-off tube connector to the charcoal canister and push up the retainer so that the claws engage.
      Fig 9: Identifying Retainer
      GTY226950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      NOTE:
      • Check that there are no scratches or foreign matter around the connected part of the fuel cut-off tube connector and pipe before performing this work.
      • After connecting the fuel cut-off tube, check that the fuel cut-off tube is securely connected by pulling on the fuel cut-off tube connector and the charcoal canister.
  8. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the No. 1 fuel tank protector with the 3 bolts.
      Fig 10: Identifying No. 1 Fuel Tank Protector Bolts
      GTY228753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  9. INSTALL REAR FLOOR STEP UNDER COVER SUB-ASSEMBLY (w/ Floor Under Cover)  . Refer to INSTALLATION - Step 2
  10. INSTALL REAR SUSPENSION BRACE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 28
  11. INSTALL REAR FLOOR SIDE MEMBER COVER LH (w/ Floor Under Cover)  . Refer to INSTALLATION - Step 29
  12. INSTALL REAR FLOOR SIDE MEMBER COVER RH (w/ Floor Under Cover)  . Refer to INSTALLATION - Step 30
  13. ADD FUEL 
  14. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Install the fuel suction tube assembly with pump and gauge. Refer to INSTALLATION .
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