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Fuel Tank: Installation

  1. INSTALL NO. 2 FUEL TANK CUSHION 
    1. Install 7 new No. 2 fuel tank cushions to the fuel tank.
      Fig 1: Identifying No. 2 Fuel Tank Cushions
      G04974968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL MAIN TUBE SUPPORT 
    1. Install the fuel main tube support with the bolt.

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

      Fig 2: Identifying Fuel Main Tube Support Bolt
      G04974967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Install the fuel pump tube to the fuel main tube support.
    Fig 3: Installing Fuel Pump Tube
    G04974966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK VENT HOSE 
    1. Install the fuel tank vent hose.
      Fig 4: Installing Fuel Tank Vent Hose
      G04974972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK ASSEMBLY 
    1. Install the 4 clip nuts (Except SE Grade).
      Fig 5: Identifying Clip Nuts (Except Se Grade)
      G04974973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 clip nuts (for SE Grade).
      Fig 6: Identifying Clip Nuts (For Se Grade)
      G04974974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 fuel tank bands with the 2 pins.
      Fig 7: Identifying Fuel Tank Bands Pins
      G04974975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Set the fuel tank assembly onto the transmission jack.
    5. 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.
      Fig 8: Locating Fuel Tank Bands Set Bolts
      G04974976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the fuel tank inlet pipe with the fuel filter pipe clamp. (*2)
    7. Tighten the 2 set bolts of the fuel tank bands. (*3)

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

    8. Connect the No. 1 fuel tube.
      1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.
        Fig 9: Locating Fuel Tube Connector
        G04974977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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.
    9. 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 10: Locating Fuel Tube Connector Retainer
        G04974978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL TANK PROTECTOR LOWER CENTER 
    1. Install the 4 bolts and fuel tank protector (Except SE Grade).

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

      Fig 11: Locating Fuel Tank Protector (Except Se Grade) Bolts
      G04974956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tank protector with the 4 bolts and 2 clips (for SE Grade).

      Torque: 

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

      Fig 12: Locating Fuel Tank Protector Bolts And Clips (For Se Grade)
      G04974957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR STABILIZER BAR NO. 1 BRACKET 
    1. Install the 2 rear stabilizer bar No. 1 brackets with the 4 bolts.

      Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 

      Fig 13: Identifying Rear Stabilizer Bar No. 1 Brackets Bolts
      G04974981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY 
    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 

      8.5 N*m (87 kgf*cm, 75 in.*lbf) 

      Fig 14: Locating No. 3 Parking Brake Cable Assembly Bolt And Nut
      G04974954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    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 

      8.5 N*m (87 kgf*cm, 75 in.*lbf) 

      Fig 15: Locating No. 2 Parking Brake Cable Assembly Bolt And Nut
      G04974953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  11. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE  (See INSTALLATION )
  12. INSTALL FUEL TANK VENT TUBE SET PLATE  (See INSTALLATION )
  13. CONNECT FUEL PUMP TUBE SUB-ASSEMBLY  (See COMPONENTS )
  14. ADD FUEL 
  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  16. CHECK FOR FUEL LEAKS  (See SYSTEM DIAGRAM )
  17. CHECK FOR EXHAUST GAS LEAKS 
  18. INSTALL REAR FLOOR SERVICE HOLE COVER 
  19. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)  (See INSTALLATION )
  20. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fold Down Seat Type)  (See INSTALLATION )
  21. INSTALL REAR SEAT CUSHION ASSEMBLY (for Reclining Seat Type)  (See INSTALLATION )
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