Fuel Tank: Installation

1. Install 7 new No. 2 fuel tank cushions to the fuel tank.
   Fig 1: Locating Fuel Tank Cushions

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the fuel main tube support with the bolt.

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

   Fig 2: Locating Fuel Main Tube Support Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the fuel pump tube to the fuel main tube support.
   Fig 3: Locating Fuel Pump Tube

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1. Install the fuel tank vent hose.
   Fig 4: Installing Fuel Tank Vent Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 4 clip nuts.
   Fig 5: Locating Clip Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 fuel tank bands with the 2 pins.
Fig 6: Installing Pins And Fuel Tank Bands
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the fuel tank assembly onto the transmission jack.
4. Raise the transmission jack so that the fuel tank vent hose can be connected (*1).
   NOTE: Slowly raise the jack to prevent the fuel tank assembly from dropping.
5. Connect the fuel tank inlet pipe with the fuel filter pipe clamp (*2).
6. Tighten the 2 set bolts of the fuel tank bands (*3).

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

   Fig 7: Locating Fuel Tank Bands Set Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the No. 1 fuel tube.
   1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.
      NOTE:

      • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on any part of the connector.
      • After connecting the connector, check if the fuel tube connector and the pipe are securely connected by pulling on them.
        Fig 8: Pushing Fuel Tube Connector Into Pipe

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Connect the fuel pump tube.
   1. Push the fuel connector into the pipe and push up the retainer so that the claws engage.
      NOTE:

      • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on any part of the connector.
      • After connecting the connector, check if the fuel tube connector and the pipe are securely connected by pulling on them.
        Fig 9: Connecting Fuel Pump Tube

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the 4 bolts and fuel tank protector.

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

   Fig 10: Locating Fuel Tank Protector Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 3 parking brake cable assembly with the bolt and nut.

   Torque: Bolt 

   6.0 N*m (61 kgf*cm, 53 in.*lbf) 

   Nut 

   5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Fig 11: Locating Set Bolt And Set Nut Of No 3 Parking Brake Cable Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 2 parking brake cable assembly with the bolt and nut.

   Torque: Bolt 

   6.0 N*m (61 kgf*cm, 53 in.*lbf) 

   Nut 

   5.4 N*m (55 kgf*cm, 48 in.*lbf) 

Fig 12: Locating Bolt And Nut Of No 2 Parking Brake Cable Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new gaskets and the exhaust pipe with the 2 bolts and 4 new nuts.

   Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

HINT:

See ON-VEHICLE INSPECTION