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Installation [08/2016 - ]: Procedure

  1. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel tank.
      GTY664400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Fuel Tank Side Mark
      *b Hose Side Mark

      HINT: 

      Align the fuel tank side mark with the hose side mark when installing the hose.

  2. INSTALL NO. 3 FUEL TANK PROTECTOR 
    1. Install the No. 3 fuel tank protector and attach the 4 clamps.
    2. Install the 2 bolts.

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

  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Apply a co-rotation prevention check mark to the fuel suction with pump and gauge tube assembly.

      HINT: 

      Perform this procedure when replacement of the fuel suction with pump and gauge tube assembly is necessary.

      GTY655375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Co-rotation Prevention Check Mark
      Front Side of Vehicle
    2. Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank sub-assembly.
    3. Set the fuel suction with pump and gauge tube assembly to the fuel tank sub-assembly.
      GTY615969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Groove
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge assembly.

      HINT: 

      Align the cutout of the fuel suction with pump and gauge tube assembly to the groove of the fuel tank sub-assembly.

    4. Temporarily place the fuel pump gauge retainer by aligning the rotational start point mark of a new fuel pump gauge retainer with the rotational start point mark of the fuel tank sub-assembly while pressing the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly.
      GTY683970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotational Start Point Mark (Fuel Tank Sub-assembly Side)
      *b Rotational Start Point Mark (Fuel Pump Gauge Retainer Side)
      Front Side of Vehicle
    5. Set 4 SSTs (claw sets) to the fuel pump gauge retainer and temporarily install.
      • SST: 09808-14031 
        1. 09808-01080
        2. 09808-01090
        3. 09808-01100
      NOTE:
      • Align the cutout of SST (claw set) to the rib of the fuel pump gauge retainer.
      • Do not place SST on the rotational start point mark of the fuel pump gauge retainer, otherwise SST (claw set) cannot be set correctly.
      GTY621473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Rib
      *c Cutout
      *d SST (Claw Set) Incorrect Installation Point (Rotational Start Point Mark of Fuel Pump Gauge Retainer)
    6. While firmly pressing the claw of SST (claw set) into rib of the fuel pump gauge retainer, tighten the bolt.
      GTY665529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Hook
      Press
      SST (Bolt)
    7. Temporarily install SST (plate) to SST (claw set) with 4 SSTs (bolts).
      GTY630024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Plate)
      *b SST (Claw Set)
      SST (Bolt)
    8. Adjust the position of SST (plate) so that the setting hole of SST (handle) aligns with the center of the fuel pump gauge retainer.
      GTY630714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Center of Fuel Pump Gauge Retainer
      *b SST (Plate)
      Front Side of Vehicle
    9. While firmly pressing the SST (claw set) into rib of the fuel pump gauge retainer, tighten SST (bolt).
      GTY652926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Gauge Retainer
      *a SST (Plate)
      *b SST (Claw Set)
      *c SST (Bolt)
      *d Rib
      Press
    10. While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly, have another person firmly press the fuel pump gauge retainer into the threads of the fuel tank sub-assembly and tighten approximately one and a half turns.
      NOTE:
      • Do not use any tools other than SST, such as a screwdriver, etc.
      • Do not use excessive force when pressing down on SST, as the fuel suction with pump and gauge tube assembly will place excessive force on the pump gauge retainer and be difficult to remove, and parts may be damaged.
      • Do not use an impact wrench or turn the SST handle with excessive force, as parts may be damaged.
      • Do not rotate the fuel pump gauge retainer when the co-rotation prevention check mark is out of place.
      GTY666267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Co-rotation Prevention Check Mark
      *b Tightening Start Position
      *c One and Half Rotation Position
      Front Side of Vehicle
    11. While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank sub-assembly, have another person slowly tighten approximately 180°.
      GTY613566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Plate)
      *b Person in Charge of Tightening
      *c Person in Charge of Supporting
      *d Approximately 180°
      Front Side of Vehicle
    12. Check the tightening condition of the fuel pump gauge retainer.
      1. Using a vernier caliper, measure the upper surface dimensions of the fuel tank sub-assembly at the 3 positions as shown in the illustration.

        Standard

        Measurement difference is within 3 mm.

        NOTE:

        If the measurement difference is approximately 6 mm, the threads misaligned by 1 threads (6 mm) and the fuel pump gauge retainer must be installed again.

        GTY620914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Sub-assembly
        *a Vernier Caliper
        *b Measurement Position
        *c Measurement Height
        Front Side of Vehicle
    13. Install SST (handle) to SST (plate).
      • SST: 09808-14031 
        1. 09808-01010
        2. 09808-01020
      GTY628756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Handle)
      *b SST (Plate)
      *c Tightening Complete Position
      *d Rotational Start Point Mark of Fuel Pump Gauge Retainer
      *e Rotational Start Point Mark of Fuel Tank Sub-assembly
      *f Person in Charge of Tightening
      *g Person in Charge of Supporting
      Tighten
    14. While one person presses the fuel suction with pump and gauge tube assembly onto the fuel tank sub-assembly, have another person use SST (handle) and slowly tighten the fuel pump gauge retainer until it reaches the tightening complete position.
  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY 
    1. Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.
      GTY284460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting parts.
        GTY632593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Tube Joint
        *2 O-Ring
        *3 Fuel Tube
        *4 Fuel Tube Joint Clip
        *a CORRECT
        *b INCORRECT
      • Check that the fuel tube joints are inserted securely.
      • Check that the fuel tube joint clips are on the collars of the fuel tube joints.
      • After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.
    2. Install the fuel tank main tube and fuel return tube to the fuel tank.
  5. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Install the fuel tank breather tube.

      Refer to PRECAUTION [08/2015 - ]

  6. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the No. 1 fuel tank protector to the fuel tank.
  7. INSTALL FUEL TANK CUSHION 
    1. Install 3 new fuel tank cushions to the fuel tank.
  8. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set the fuel tank on a transmission jack and lift up the transmission jack.
    2. Install the 2 fuel tank bands with the 2 pins and 2 clips.
    3. Connect the 2 fuel tank bands with the 2 bolts.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  9. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose to the filler pipe.
  10. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank breather tube.

      Refer to PRECAUTION [08/2015 - ]

  11. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Connect the fuel tank vent hose.

      Refer to PRECAUTION [08/2015 - ]

  12. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY 
    1. Connect the fuel return tube.

      Refer to PRECAUTION [08/2015 - ]

  13. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube.

      Refer to PRECAUTION [08/2015 - ]

  14. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. for Half Cover Type:

      Install the No. 1 fuel tank protector with the 4 bolts.

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

    2. for Standard Type:

      Install the No. 1 fuel tank protector with the 6 bolts.

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

  15. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel pump and fuel sender gauge connector.
    2. Install the rear floor service hole cover with the 3 screws.
  16. INSTALL REAR SEAT ASSEMBLY LH 
  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [08/2015 - 08/2019] , or refer to INITIALIZATION [08/2019 - 08/2021] , or refer to INITIALIZATION [08/2021 - 08/2022] , or refer to INITIALIZATION [08/2022 - ]

  18. INSPECT FOR FUEL LEAK 

    See step  18

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