LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Matrix Base, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 11 (Engine Fuel System (2AZ-FE)) >> Fuel Tank >> Installation

Fuel Tank: Installation

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL NO. 1 FUEL TANK CUSHION (for 4WD) 
    1. Install new No. 1 fuel tank cushions onto the fuel tank.
    Fig 1: Locating No. 1 Fuel Tank Cushion (4WD)
    G06041953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 3 FUEL TANK CUSHION (for 4W0) 
    1. Install new No. 3 fuel tank cushions onto the fuel tank.
    Fig 2: Locating No. 3 Fuel Tank Cushion (4W0)
    G06041957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK CUSHION (for 2WD) 
    1. Install new fuel tank cushions onto the fuel tank.
    Fig 3: Locating Fuel Tank Cushion (2WD)
    G06041955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK VENT HOSE (for 4WD) 
    1. Install the fuel tank vent hose.
    Fig 4: Locating Fuel Tank Vent Hose (4WD)
    G06041951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK VENT HOSE (for 2WD) 
    1. Install the fuel tank vent hose onto the fuel tube clamp.
    Fig 5: Locating Fuel Tank Vent Hose (2WD)
    G05193300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Install the fuel tank main tube onto the fuel tank.
  7. INSTALL FUEL TANK ASSEMBLY (for 4WD) 
    1. Set the fuel tank on a transmission jack.
      Fig 6: Locating Fuel Tank Main Tube
      G05193299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Operate the transmission jack, then install the fuel tank into the vehicle.
      Fig 7: Holding Fuel Tank With Transmission Jack
      G06041946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 No. 1 fuel tank bands with the 4 bolts.

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

      Fig 8: Locating No. 1 Fuel Tank Bands And Bolts
      G06041947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FUEL TANK ASSEMBLY (for 2WD) 
    1. Set the fuel tank on a transmission jack.
    2. Operate the transmission jack, then install the fuel tank into the vehicle.
      Fig 9: Holding Fuel Tank With Transmission Jack
      G06009804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 No. 1 fuel tank bands with the 4 bolts.

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

    Fig 10: Locating No. 1 Fuel Tank Bands And Bolts
    G06009805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL TANK FILLER PIPE SUB-ASSEMBLY 
    1. Connect the fuel tank filler pipe hose to the fuel tank.
      NOTE: Make sure that the hose clamp is facing the correct direction when installing.
      Fig 11: Identifying Fuel Tank Filler Pipe Hose Clamp Tightening Angle
      G05193306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
    Fig 12: Identifying Fuel Tank Filler Pipe Cover Claw
    G06009802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
        Fig 13: Aligning Fuel Tube Connector With Pipe
        G06041968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
        • After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.
  11. CONNECT BREATHER TUBE FUEL HOSE 
    1. Connect the breather tube fuel hose.
      Fig 14: Locating Breather Tube Fuel Hose
      G06009800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the breather tube fuel hose.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
        Fig 15: Connecting Breather Tube Fuel Hose
        G06041970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
        • After connecting the breather tube fuel hose, check that the fuel pump tube is securely connected by pulling on the fuel tube connector and pipe.
      2. Install the checker onto the pipe.
  12. CONNECT FUEL TANK VENT HOSE (for Torsion Beam Type Suspension) 
    1. Connect the fuel tank vent hose.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
      2. Slide the retainer of the fuel tube connector to lock the claws as shown in the illustration.
        NOTE:
        • Check that there are no scratches or foreign objects around the connecting surfaces 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 on the fuel tube connector.
        Fig 16: Sliding Retainer Of Fuel Tube Connector To Lock Claws
        G06041812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY (for Double Wishbone Type Suspension) 
  14. INSTALL CHARCOAL CANISTER ASSEMBLY (for Double Wishbone Type Suspension) 

    HINT:

  15. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY (for 4WD) 
    1. Install the fuel tank protector sub-assembly with the 4 bolts and 2 nuts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

    Fig 17: Locating Fuel Tank Protector Bolts And Nut
    G06041938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY (for 2WD) 
    1. Install the fuel tank protector sub-assembly with the 4 bolts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 18: Locating Fuel Tank Protector Bolts
      G06009797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. CONNECT PARKING BRAKE CABLE 
    1. Install the parking brake cables with the 4 bolts.

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

  18. TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)  (See INSTALLATION )
  19. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY  (See INSTALLATION )
  20. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 4WD) 

    HINT:

    See INSTALLATION

    Fig 19: Locating Parking Brake Cables With Bolts
    G06041937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2WD) 

    HINT:

    See INSTALLATION

  22. ADD FUEL 
  23. INSTALL FUEL SENDER GAUGE RH ASSEMBLY (for 4WD)  (See INSTALLATION )
  24. INSTALL FUEL SUCTION TUBE ASSEMBLY 
    1. Install the fuel suction tube assembly to the fuel tank assembly (See INSTALLATION  ).
  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  26. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  27. INSPECT FOR EXHAUST GAS LEAK 
  28. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER (for 4WD)  (See INSTALLATION )
scientia non olet · About LEMON Manuals