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Fuel Tank: Reassembly

  1. INSTALL NO. 1 FUEL TANK CUSHION 
    1. Install 10 new fuel tank cushions onto the fuel tank as shown in the illustration.
      Fig 1: Locating No. 1 Fuel Tank Cushion
      G04865768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 4 FUEL TUBE CLAMP 
    1. Install the fuel tube clamp with the bolt.

      Torque: 6.0 N*m (60 kgf*cm, 53 in.*lbf) 

      Fig 2: Locating Fuel Tube Clamp With Bolt
      G04865767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 3 FUEL TUBE CLAMP 
    1. Align the clip positions, then install the fuel tube clamp.
      Fig 3: Aligning Clip Positions
      G04865766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TANK SUCTION TUBE SUPPORT 
    1. Align the clip position, then install the tank suction tube support.
      Fig 4: Locating Tank Suction Tube Support Clip
      G04865772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 3 FLOOR WIRE 
    1. Align the claws positions, then install the fuel tank protector plate.
    2. Install the wire harness clamp.
      Fig 5: Separating Claws Fittings
      G04865764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the floor wire with the 3 wire harness clamps.
      Fig 6: Locating Wire Harness Clamps
      G04865763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL TANK VENT HOSE 
    1. Align the hose connector with the pipe, then push in the hose connector until it comes into contact with the seat to connect the fuel tank vent hose to the pipe. Then push the retainer up until to the claws lock.
      Fig 7: Aligning Hose Connector With Pipe
      G04865775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hose into the hose clamp.
      NOTE:
      • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the hose connector and pipe.
  7. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Fit the fuel tank main tube into the fuel tube clamp and tank suction tube support.
    2. Fig 8: Locating Fuel Tube Clamp
      G04865761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002