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Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the tank protector with the 2 nuts.

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

      Fig 1: Locating Tank Protector With Nuts
      G05287087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK CUSHION 
    1. Install the tank cushions and tank brackets.
      Fig 2: Locating Tank Cushions And Fuel Tank Brackets
      G05805694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Install the fuel tank return vent tube and the fuel pump tube to the 2 clamps.
  4. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set an engine lifter to the fuel tank and lift it up.
    2. Install the 2 fuel tank bands with the 4 bolts to install the fuel tank.

      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: Locating Fuel Pump Tube Sub-Assembly Clamps
      G05805693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CONNECT FUEL EMISSION HOSE 
    1. Connect the 2 fuel emission hoses.
    2. Connect the fuel tank bracket hose.
      Fig 4: Locating Fuel Emission Hoses And Fuel Tank Bracket Hose
      G05287083Courtesy 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: Locating Filler Pipe Hose From Fuel Tank Filler Pipe
      G05287211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (for LH Side) 
    1. Connect the fuel pump tube connector.
      1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
        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.
          Fig 6: Pushing Up Retainer To Engage Claws
          G05805701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT FUEL TANK RETURN VENT TUBE 
    1. Connect the fuel tank return vent tube connector.
      1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
        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.
          Fig 7: Pushing Fuel Tube Connector To Pipe
          G05805702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (for RH Side) 
    1. Connect the fuel pump tube connector.
      1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
        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.
          Fig 8: Connecting Fuel Pump Tube Sub-Assembly
          G05805703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT PARKING BRAKE CABLE ASSEMBLY 
    1. Connect the 4 clamps.
    2. Connect the 2 parking brake cables with the 4 bolts.

      Torque: bolt A 

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

      bolt B 

      19 N*m (193 kgf*cm, 14 ft.*lbf) 

  11. INSTALL REAR SUSPENSION MEMBER BRACE REAR LOWER LH  (See REPLACEMENT )
  12. INSTALL REAR SUSPENSION MEMBER BRACE REAR LOWER RH  (See REPLACEMENT )
    Fig 9: Locating Parking Brake Cables With Bolts And Clamps
    G05287096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR FLOOR SIDE MEMBER COVER LH  (See REPLACEMENT )
  14. INSTALL REAR FLOOR SIDE MEMBER COVER RH  (See REPLACEMENT )
  15. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Install the differential support protector with the 2 nuts.
  16. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Install the differential support protector with the 2 nuts.
      Fig 10: Locating Differential Support Protector Nuts
      G05287075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 2 FUEL TANK PROTECTOR 
    1. Install the tank protector with the 4 nuts.

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

  18. INSTALL REAR PROPELLER SHAFT ASSEMBLY 
    1. Install the rear propeller shaft assembly (See INSTALLATION ).
      Fig 11: Locating Fuel Tank Protector Nuts
      G05287074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY 
    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 12: Setting Fuel Sender Gauge To Fuel Vent Tube
        G05805707Courtesy 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 fuel suction tube set gasket, and set it to the fuel tank.
    4. Connect the fuel tube connector, and set the fuel suction with pump and gauge tube.
      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.
      Fig 13: Aligning Protrusion Of Fuel Suction Tube And Cutout Of Fuel Tank
      G05805708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 14: Aligning Starting Marks Of Fuel Pump Gauge Retainer And Fuel Tank
      G05287233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a 6 mm socket, set SST to the fuel pump gauge retainer.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      NOTE: Do not use any other tools such as a screwdriver.

      HINT:

      Fit the tips of SST on the ribs of the retainer.

      Fig 15: Setting SST To Fuel Pump Gauge Retainer
      G05805680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the start mark on the retainer is within the indicated range in the illustration.
      Fig 16: Tightening Fuel Pump Gauge Retainer
      G05805711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 TUBE ASSEMBLY WITH PUMP AND GAUGE  (See REASSEMBLY  )
  22. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION  )
  23. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER  (See INSTALLATION  )
    Fig 17: Locating Service Hole Cover
    G05805679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL ROOM NO. 3 PARTITION PAD  (See INSTALLATION  )
  25. INSTALL REAR SEAT CUSHION ASSEMBLY  (See INSTALLATION )
  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
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