Fuel Tank: Installation

1. Install the No. 2 fuel tank protector to the fuel tank assembly.
   Fig 1: Installing No 2 Fuel Tank Protector To Fuel Tank Assembly

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1. Install 11 new fuel tank cushions shown in the illustration.
   Fig 2: Identifying Fuel Tank Cushions

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1. Connect the fuel tank vent hose to the fuel tank.
   Fig 3: Connecting Fuel Tank Vent Hose To Fuel Tank

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1. Install the fuel tank to filler pipe hose to the fuel tank with the clamp.
2. Tighten the hose clamp bolt.
   Fig 4: Identifying Fuel Tank, Filler Pipe Hose, And Fuel Tank With Clamp

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1. Install the edge protector with the 2 clamps.
   Fig 5: Identifying Edge Protector With 2 Clamps

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2. Install a fuel tank main tube and fuel tank return vent tube with the clamp.

1. Install a new gasket to the No. 1 fuel tank breather tube sub-assembly.
   Fig 6: Identifying Gasket And No 1 Fuel Tank Breather Tube Sub-Assembly

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2. Install the No. 1 fuel tank breather tube subassembly with the 4 bolts.
   Fig 7: Identifying No 1 Fuel Tank Breather Tube Subassembly With 4 Bolts

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   Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

1. Set a engine lifter to the fuel tank and lift it up.
2. Install the 2 fuel tank bands with the 4 bolts.
   Fig 8: Identifying Fuel Tank Bands With 4 Bolts

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

1. Connect the fuel tank to canister tube subassembly.
   1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
      Fig 9: Connecting Fuel Tank To Canister Tube Subassembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check for damage or foreign objects on the connected part.
   • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

1. Connect the No. 3 fuel hose sub-assembly with the clip.
2. Connect the fuel hose clamp.
   Fig 10: Identifying No 3 Fuel Hose Sub-Assembly With Clip

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1. Connect the fuel tank to filler pipe hose with the clamp.
   Fig 11: Identifying Fuel Tank And Filler Pipe Hose With Clamp

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1. Connect the fuel tank main tube (RH side).
   1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
      Fig 12: Identifying Fuel Tank Main Tube (RH Side)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check for damage or foreign objects on the connected part.
   • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
2. Connect the fuel tank return vent tube.
   1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
      Fig 13: Identifying Fuel Tank Return Vent Tube

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • Check for damage or foreign objects on the connected part.
   • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
3. Connect the fuel tank main tube (LH side).
   1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
      Fig 14: Identifying Fuel Tank Main Tube (LH Side)

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   NOTE:

   • Check for damage or foreign objects on the connected part.
   • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

1. Connect the 4 clamps.
2. Connect the 2 parking brake cables with the 4 bolts.
   Fig 15: Identifying Parking Brake Cables With 4 Bolts

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   Torque: 

   1. 6.0 N*m (61 kgf*cm, 53 in.*lbf) for bolt A 
   2. 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt B 

1. Install the suspension member brace lower LH with the 4 bolts.

   Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

   Fig 16: Identifying Suspension Member Brace Lower LH With 4 Bolts

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1. Install the suspension member brace lower RH with the 4 bolts.

   Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

HINT:

Installation procedure of the No. 1differential support protector is the same as that of the No. 2 differential support protector.

Fig 17: Identifying Suspension Member Brace Lower RH With 4 Bolts

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HINT:

See INSTALLATION .

HINT:

See INSTALLATION .

1. Install the fuel sender gauge with the 5 bolts to the fuel tank.

   Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

   Fig 18: Identifying Fuel Sender Gauge With 5 Bolts To Fuel Tank

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2. Connect the fuel sender gauge connector.

1. Install the service hole cover with new butyl tape.

1. Perform initialization (See INITIALIZATION ).

   HINT:

   Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.