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Installation (To 10/2008)

  1. INSTALL NO. 1 FUEL TANK CUSHION 
    Fig 1: Identifying Fuel Tank Cushions
    GTY123982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Attach the fuel tank cushions to the areas marked with diagonal lines in the illustration.
  2. INSTALL FUEL SENDER GAUGE 
    1. Install a new gasket and the sender gauge to the fuel tank with the 5 screws.

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

  3. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the breather tube to the fuel tank.
  4. INSTALL VENT LINE HOSE 
    1. Connect the hose to the fuel tank.
  5. CONNECT FUEL INLET TUBE 
    1. Connect the fuel inlet tube to the fuel tank.
  6. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
  7. INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY 
    Fig 2: Identifying Fuel Sub-Suction Hose
    GTY144705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install a new gasket to the fuel suction plate.
    2. Connect the fuel sub-suction hose to the fuel return jet tube.
    3. Attach the fuel pump and sender gauge to the fuel tank.
  8. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the set plate with the 8 bolts.

      Torque: 6.0 N*m ( 61 kgf*cm, 52 in.*lbf) 

  9. INSTALL FUEL TANK ASSEMBLY 
    1. Install the fuel tank and fuel tank band with the 4 bolts.

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

  10. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the filler pipe with the 2 bolts.
    2. Connect the air inlet tube to the filler pipe.
    3. Connect the fuel inlet tube to the filler pipe.
    4. Connect the breather tube to the filler pipe.
  11. CONNECT VENT LINE HOSE 
    1. Connect the vent line hose to the canister.
  12. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY 
  13. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY 
  14. INSTALL PROPELLER SHAFT ASSEMBLY  . Refer to INSTALLATION - Step 1
  15. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR 
  16. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 
  17. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR 
    1. Install the front floor heat insulator with the 4 bolts.

      Torque: 5.4 N*m ( 55 kgf*cm, 47 in.*lbf) 

  18. INSTALL PROPELLER SHAFT HEAT INSULATOR 
  19. INSTALL EXHAUST PIPE ASSEMBLY 
    1. Install the exhaust pipe assembly. Refer to INSTALLATION .
  20. INSTALL NO. 2 ENGINE UNDER COVER  . Refer to INSTALLATION - Step 4
  21. INSTALL FRONT FLOOR BRACE CENTER 
  22. INSTALL REAR FLOOR SERVICE HOLE COVER 
  23. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    Fig 3: Attaching Fuel Tube Connector To Port Of Fuel Suction Plate
    GTY144707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the connector on the fuel tank side.
      1. Attach the fuel tube connector to the port of the fuel suction plate.
      2. Install the tube joint clip.
    2. Connect the connector on the fuel pipe side.
      1. Insert the connector by aligning the axes of the pipe and connector until the retainer makes a click sound.
        NOTE:
        • Check for damage and dirt contamination in the pipe and around the connector.
        • After having finished the connection, check if the pipe and connector are securely connected by trying to pull them apart.
    3. Connect the fuel pump connector.
  24. ADD FUEL 
  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  26. PERFORM INITIALIZATION 
    1. Perform initialization. Refer to INITIALIZATION .
      NOTE:

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

  27. CHECK FUEL PUMP OPERATION AND FOR FUEL LEAKS  . Refer to ON-VEHICLE INSPECTION - Step 1
  28. CHECK FOR EXHAUST GAS LEAKS 
  29. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
  30. INSTALL REAR SEAT CUSHION ASSEMBLY  . Refer to INSTALLATION - Step 6
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