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Fuel Tank: Installation

  1. INSTALL FUEL TANK SIDE PLATE 
    1. Install the side 4 plates to the fuel tank.
      Fig 1: Installing Fuel Tank Side Plate
      G04227165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 1 FUEL TUBE CLAMP 
    1. Attach the clamp to the fuel tank.
      Fig 2: Attaching Clamp To Fuel Tank
      G04227166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK INLET VALVE ASSEMBLY 
    1. Install a new gasket and the inlet valve to the fuel tank.
      NOTE: When removing or installing the fuel tank inlet valve, be careful as it is made from resin and will be easily damaged.
  4. INSTALL CHECK VALVE SUPPORT 
    1. Install the valve support with the 3 bolts as shown in the illustration.
      Fig 3: Installing Check Valve Support
      G04227167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

      HINT:

      • Angle of A: Approximately 20°
      • Angle of B: Approximately 25°
  5. INSTALL FUEL TANK VENT HOSE 
    1. Pull up the retainer and install the vent hose.
    2. Connect the retainer.
      Fig 4: Installing Fuel Tank Vent Hose
      G04227168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 FUEL EVAPORATION TUBE SUB-ASSEMBLY 
    1. Install the No. 2 fuel evaporation tube.
  7. INSTALL CHECK VALVE PROTECTOR 
    1. Install the protector with the 3 bolts.
      Fig 5: Installing Check Valve Protector
      G04227169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

  8. INSTALL NO. 3 FUEL TUBE CLAMP 
    1. Attach the clamp to the fuel tank.
      Fig 6: Attaching Clamp To Fuel Tank
      G04227170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL PUMP ASSEMBLY WITH FUEL SENDER GAUGE ASSEMBLY (See  INSTALLATION   ) 
  10. CONNECT NO. 2 FUEL EVAPORATION TUBE SUB-ASSEMBLY (See  INSTALLATION   ) 
  11. INSTALL FUEL TANK VENT TUBE SET PLATE BOLT (See  INSTALLATION   ) 
  12. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (See  INSTALLATION   ) 
  13. INSTALL FUEL TANK ASSEMBLY 
    1. Install the fuel tank with the 4 bolts as shown in A, B, C and F in the illustration below.

      Torque: 14.3 N*m (146 kgf*cm, 11 ft.*lbf) 

    2. Connect the fuel pump tube as shown in illustration E below.
      1. Check that there is no damage or contamination in the connected part of the pipe.
        Fig 7: Pushing Pipe Into Connector
        G04227171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Align the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. if the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.
      3. After having finished the connection, try to pull apart the pipe and the connector, and confirm that they are securely connected.
        Fig 8: Checking Proper Connection Of Pipe And Connector
        G04227172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Attach the lock claws to the connector by pushing down on the checker, as shown in the illustration.
        Fig 9: Attaching Lock Claws To Connector By Pushing Down On Checker
        G04227173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the fuel tank vent hose to the canister as shown in illustration D below.

      HINT:

      Pull up the retainer and install the vent hose, and then connect the retainer.

    4. Connect the fuel vapor hose to the fuel tank as shown in illustration C below.
    5. Connect a new fuel tank to filler pipe hose to the fuel tank and fuel inlet pipe as shown in illustration C below.
      1. Tighten the 2 clamps of the fuel tank to filler pipe hose as shown in the illustration.
        Fig 10: Connecting Fuel Tank To Filler Pipe Hose To Fuel Tank And Fuel Inlet Pipe
        G04227174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the protector with the 2 clamps and fuel tank protector bracket as shown in illustration G below.
  15. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    1. Connect the 2 cable clamps with the 2 bolts as shown in illustration B below.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  16. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Connect the 2 cable clamps with the 2 bolts as shown in illustration A below.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    Fig 11: Tightening Clamps Of Fuel Tank To Filler Pipe Hose
    G04227175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL EXHAUST PIPE ASSEMBLY 
    1. Install the exhaust pipe (see INSTALLATION ).
  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  19. ADD FUEL 
  20. CHECK FOR FUEL LEAKS (See  FUEL INJECTOR   ) 
  21. INSTALL REAR FLOOR SERVICE HOLE COVER (See  INSTALLATION   ) 
  22. INSTALL REAR SEAT CUSHION SUPPORT BRACKET SUB-ASSEMBLY (See  INSTALLATION   ) 
  23. INSTALL REAR SEAT CUSHION ASSEMBLY (See  INSTALLATION  ) 
  24. CHECK FOR EXHAUST GAS LEAKS 
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