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Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK PROTECTOR SUBASSEMBLY 
    1. Install the tank protector with the 2 nuts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 1: Identifying Tank Protector With Nuts
      G04018756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK CUSHION 
    1. Install the tank cushions and tank brackets.
      Fig 2: Identifying Tank Cushions And Tank Brackets
      G04018757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Install the fuel pump tube to the 4 clamps.
  4. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set a mission jack to the fuel tank and lift it up.
    2. Install the 2 fuel tank bands with the 4 bolts.

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

    3. Install the 2 nuts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 3: Identifying Fuel Tank Bands With Bolts
      G04018758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT EMISSION HOSE 
    1. Connect the 2 emission hoses.
      Fig 4: Identifying Emission Hoses
      G04018759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose with the clamp.
      Fig 5: Identifying Fuel Tank To Filler Pipe Hose With Clamp
      G04018760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel pump tube connector.

      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. Install the fuel hose connector cover to the pipe.
      Fig 6: Identifying Fuel Hose Connector Cover To Pipe
      G04018761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT FUEL RETURN TUBE 
    1. Connect the fuel return tube and install the retainer.
      Fig 7: Identifying Fuel Return Tube
      G04018762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Connect the 4 clamps.
    2. Connect the 2 parking brake cables with the 4 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) for bolt A 19 N*m (193 kgf*cm, 14 ft.*lbf) for bolt B 

      Fig 8: Identifying Parking Brake Cables With Bolts
      G04018763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL REAR FLOOR SIDE MEMBER COVER LH 
    1. Install the member cover with the 2 bolts.
      Fig 9: Identifying Member Cover With Bolts
      G04018764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR FLOOR SIDE MEMBER COVER RH 
    1. Install the member cover with the 2 bolts.
      Fig 10: Identifying Member Cover With Bolts
      G04018765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Install the differential supporter with the 2 nuts.
  13. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Install the differential supporter with the 2 nuts.
      Fig 11: Identifying Differential Supporter With Nuts
      G04018766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 2 FUEL TANK PROTECTOR 
    1. Install the tank protector with the 4 nuts.

      Torque: 5.0 N*m (51 kgf*cm, 48 in.*lbf) 

  15. ADJUST PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See  REMOVAL  ) 
    Fig 12: Identifying Tank Protector With Nuts
    G04018767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR 
    1. Install the heat insulator with the 4 nuts.
      Fig 13: Identifying Heat Insulator With Nuts
      G04018768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT FLOOR COVER CENTER RH 
    1. Install the floor cover center with the 3 nuts.
  18. INSTALL EXHAUST PIPE ASSEMBLY 
    1. Install the exhaust pipe (see INSTALLATION ).
      Fig 14: Identifying Exhaust Pipe
      G04018769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL RETURN VENT TUBE SUBASSEMBLY 
    1. Install the fuel sender gauge.
      1. Set the fuel sender gauge to the fuel vent tube. Then slide the sender gauge downward to install it.
      2. Connect the fuel sender gauge connector.
        Fig 15: Identifying Fuel Sender Gauge Connector
        G04018770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set the fuel return vent tube to the fuel tank.
    3. Apply a light coat of gasoline to a new gasket, and set it to the fuel tank.
    4. Connect the fuel tube connector, and set the fuel suction with pump and gauge.
      Fig 16: Setting Fuel Suction With Pump And Gauge
      G04018771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • When connecting the fuel tube connector, do not forcibly pull the tube.
    5. Align the protrusion of the fuel suction tube and the cutout of the fuel tank.
    6. While holding the fuel suction tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Install the fuel pump retainer to the fuel tank.
      Fig 17: Aligning Starting Marks Of New Fuel Pump Gauge Retainer
      G04018772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a 6 mm socket, set SST to the fuel pump gauge retainer.

      SST 09808-14020 

      HINT:

      Fit the rib on the fuel pump gauge retainer into the cutout of SST.

      NOTE: Use SST. Do not any other tools such as a screwdriver.
      Fig 18: Setting SST To Fuel Pump Gauge Retainer
      G04018773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Hold SST with one hand use SST to tighten the fuel pump gauge retainer 2 turns so that the starting mark on the retainer is within the in the indicated range in the illustration.
      Fig 19: Tightening Fuel Pump Gauge Retainer
      G04018774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the fuel return tube and pump tube.
      1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
    10. Connect the fuel suction tube connector.
      Fig 20: Identifying Fuel Suction Tube Connector
      G04018775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there are no scratches or foreign matter around the connected parts of the fuel tube joint and plug before performing this work.
      • Check that the fuel tube joint is securely inserted.
      • Check that the tube joint clip is on the collar of the fuel tube joint.
      • After installing the tube joint clip, check that the fuel tube cannot be pulled out.
  20. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel sender gauge connector.
    2. Install the service hole cover with new butyl tape.
  21. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (see  INSTALLATION   ) 
    Fig 21: Identifying Fuel Suction With Pump And Gauge Tube Assembly
    G04018776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel pump connector.
    2. Install the service hole cover with new butyl tape.
      Fig 22: Identifying Service Hole Cover With New Butyl Tape
      G04018777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL NO. 3 ROOM PARTITION PAD 
    1. Install the partition pad with the clip.
  24. INSTALL REAR SEAT CUSHION ASSEMBLY (See  INSTALLATION  ) 
  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  26. CHECK FOR FUEL LEAKS (see   3  ) 
  27. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      Fig 23: Identifying Partition Pad With Clip
      G04018778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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