Fuel Tank: Installation

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
1. Apply a light coat of gasoline or grease to a new gasket, and install it to the fuel tank.
2. Install the fuel suction with pump and gauge tube into the fuel tank.
  NOTE:
  - Be careful not to bend the arm of the fuel sender gauge.
  - Align the protrusion of the pump and gauge tube with the groove of the fuel tank.
    
    Fig 1: Aligning Protrusion Of Pump And Gauge Tube With Groove Of Fuel Tank
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Put the retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer one complete turn by hand.
4. Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank, as shown in the illustration.
  SST 09808-14020 (09808-01410, 09808-01420, 09808-01430)
  
  HINT:
  
  Fit the tips of SST onto the ribs of the retainer.
  
  Fig 2: Tightening Retainer Until Mark On Retainer Is Within Range A On Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the 2 fuel tank tubes with the 2 tube joint clips.
  
  Fig 3: Installing Fuel Tank Tubes With Tube Joint Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check that there are no scratches or foreign objects on the connecting parts.
  - Check that the fuel tube joints are inserted securely.
  - Check that the tube joint clips are on the collars of the fuel tube joints.
  - After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
    
    Fig 4: Checking Tube Joint Clips Are On Collars Of Fuel Tube Joints
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK TO FILLER PIPE HOSE
1. Install the filler pipe hose to the fuel tank.
  
  Fig 5: Locating Filler Pipe Hose Of Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FUEL TANK HEAT INSULATOR
1. Install the heat insulator with the 4 clips and nut.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 6: Locating Heat Insulator Clips And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK INLET PIPE SUB-ASSEMBLY
1. Install the inlet pipe with the 2 nuts.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 7: Locating Inlet Pipe With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK ASSEMBLY
1. Set the fuel tank on a mission jack and raise the fuel tank.
2. Connect the harness clamp and fuel pump connector to the fuel tank.
  NOTE: Be careful not to cut the wirings.
3. Raise the mission jack.
4. Install the 2 fuel tank bands with the 2 pins and 2 clips.
  
  Fig 8: Locating Fuel Tank Bands Pins And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the 2 fuel tank bands with the 2 bolts.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 9: Locating Fuel Tank Bands Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 1 CANISTER OUTLET HOSE
1. Connect the canister outlet hose to the inlet pipe.
2. Attach the hose to the No. 1 breather tube clamp.
CONNECT FUEL TANK TO FILLER PIPE HOSE
1. Connect the fuel tank to filler pipe hose to the inlet pipe.
2. Connect the fuel tank breather tube to the inlet pipe.
  HINT:
  
  Push the parts together firmly until a "click" sound is heard.
  NOTE:
  - Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
  - After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
3. Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
4. Attach the filler pipe hose and breather tube to the No. 1 breather tube clamp.
Fig 10: Connecting Fuel Tank To Filler Pipe Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT WIRE HARNESS
1. Attach the harness clamp to the fuel tank.
  
  Fig 11: Attaching Harness Clamp To Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT VENT LINE HOSE
1. Connect the vent line hose and install the retainer.
  NOTE:
  - Before installing the hose, make sure that it is not damaged. Make sure that there is no foreign matter present on the connecting surfaces.
  - After connecting, check if the hose and the connector are securely connected by pulling on them.
    
    Fig 12: Connecting Vent Line Hose
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK RETURN TUBE
1. Connect the fuel tank return tube.
  HINT:
  
  Push the parts together firmly until a "click" sound is heard.
  NOTE:
  - Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
  - After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
2. Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
  
  Fig 13: Attaching Lock Claws To Connector By Pushing Down On Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Connect the fuel tank main tube.
  HINT:
  
  Push the parts together firmly until a "click" sound is heard.
  NOTE:
  - Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
  - After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
2. Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (for Rough Road Area Specification Vehicles)
1. Install the tank protector with the 2 bolts and 2 nuts.
  Torque:
  
  for bolt
  
  29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  for nut
  
  20 N*m (204 kgf*cm, 15 ft.*lbf)
  
  Fig 14: Attaching Lock Claws To Connector By Pushing Down On Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK CAP
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
INSPECT FOR FUEL LEAK (see INSTALLATION )