Fuel Tank: Installation

1. Install the No. 2 fuel tank protector to the fuel tank assembly.

Fig 1: Identifying No. 2 Fuel Tank Protector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 11 new fuel tank cushions shown in the illustration.

Fig 2: Identifying Fuel Tank Cushions

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the fuel tank vent hose to the fuel tank.

Fig 3: Connecting Fuel Tank Vent Hose To Fuel Tank

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the fuel tank to filler pipe hose to the fuel tank with the clamp.
2. Tighten the hose clamp bolt.

Fig 4: Locating Hose Clamp Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating Clamp Of Fuel Tank Main Tube And Fuel Tank Return Vent Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 fuel tank breather tube sub-assembly with the 4 bolts.

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

Fig 7: Locating No. 1 Fuel Tank Breather Tube Sub-Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set a engine lifter 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) 

Fig 8: Locating Fuel Tank Bands Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the fuel tank to canister tube sub-assembly.
   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 9: Pushing In Fuel Tube Connector To Pipe

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the No. 3 fuel hose sub-assembly with the clip.
2. Connect the fuel hose clamp.

Fig 10: Locating No. 3 Fuel Hose Sub-Assembly Clip

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the fuel tank to filler pipe hose with the clamp.

Fig 11: Locating Fuel Tank To Filler Pipe Hose Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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.
   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 12: Connecting Fuel Tank Main Tube (RH Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
   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 13: Connecting Fuel Tank Return Vent Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
   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 14: Connecting Fuel Tank Main Tube (LH Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 (194 kgf*cm, 14 ft.*lbf) for bolt B 

   Fig 15: Locating Parking Brake Cables And Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Fig 16: Locating Suspension Member Brace Lower LH Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

   Fig 17: Locating Suspension Member Brace Lower RH Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

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

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: Locating Fuel Sender Gauge Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the fuel sender gauge connector.

Fig 19: Locating Fuel Sender Gauge Connector

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Fig 20: Identifying Service Hole Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Perform initialization (See INITIALIZATION ).

   HINT:

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