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Fuel Tank: Installation: Installation

  1. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Connect a new fuel tank to filler pipe hose, as shown in the illustration, with the clamp.
      Fig 1: Identifying Fuel Tank To Filler Pipe Hose With Clamp
      GTY192727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Push the tube connector into the pipe until the connector makes a "click" sound and install the retainer.
      Fig 2: Identifying Fuel Tank Breather Tube Sub-Assembly And Retainer
      GTY173890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Push
      NOTE:
      • Check if there is any damage or foreign matter on the connected part of the pipe.
      • After connecting, check if the pipe and the connector are securely connected by pulling them.
  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY  See step  1
  4. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Install the fuel tank main tube and return tube with the 2 joint clips.
      Fig 3: Identifying Joint Clips And Fuel Tank Tubes
      GTY186146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 O-Ring
      Push
      NOTE:
      • Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work.
      • Check that the fuel tube joint is securely inserted into the end.
      • Check that the tube joint clips are on the collar of the fuel tube joint.
      • After installing the tube joint clip, check that the fuel tank main tube and return tube can be pulled out.
  5. INSTALL FUEL TANK CUSHION 
    1. Install 4 new fuel tank cushions to the fuel tank.
  6. INSTALL NO. 3 FUEL TANK PROTECTOR 
    1. Install the No. 3 fuel tank protector with the 2 bolts and 3 claws.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  7. INSTALL FUEL TANK ASSEMBLY 
    1. Set a mission jack to the fuel tank.
    2. Install the fuel tank and 2 fuel tank bands with the 2 clips, 2 pins and the 2 bolts.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  8. INSTALL FUEL TANK VENT HOSE 
    1. Connect the fuel tank vent hose.
      Fig 4: Identifying Fuel Tank Vent Hose
      GTY173892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Push
      1. Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent connector until the retainer makes a "click" sound to connect the fuel tank vent hose to the charcoal canister.
        NOTE:
        • Check that there are no scratches or foreign matter on the disconnected parts of the fuel tank vent connector and pipe before performing the work.
        • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the quick connector.
  9. CONNECT FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE 
    1. Push the tube connector into the pipe until the connector makes a "click" sound.
      Fig 5: Identifying Tube Connectors And Pipe
      GTY179794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Retainer
      *2 O-Ring
      *a Lock
      *b Unlock
      NOTE:
      • Check that there is no damage or foreign objects on the connected part of the pipe.
      • After connecting, check if the pipe and the connector are securely connected by pulling them.
  10. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Push the tube connector into the pipe until the connector makes a "click" sound.
      Fig 6: Identifying Tube Connector And Pipe
      GTY173893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Push
      NOTE:
      • Check that there is no damage or foreign objects on the connected part of the pipe.
      • After connecting, check if the pipe and the connector are securely connected by pulling them.
  11. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose, as shown in the illustration, with the clamp.
      Fig 7: Identifying Clamp Bolt
      GTY167914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (for Automatic Transmission) 
    1. Install the fuel tank protector with the 4 nuts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    2. Install the fuel tank protector bracket with the 2 nuts.

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

  13. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY (for Manual Transmission) 
    1. Install the fuel tank protector with the 4 nuts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    2. Install the fuel tank protector bracket with the nut.

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

  14. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the connector.
    2. Install the 3 screws from the center floor.
    3. Install the center floor silencer pad LH.
    4. Install the floor carpet.
  15. INSTALL REAR DOOR SCUFF PLATE LH 
    1. Engage the 6 claws and install the rear door scuff plate.
  16. INSTALL FRONT DOOR SCUFF PLATE LH 
    1. Engage the 14 claws and install the front door scuff plate.
  17. INSTALL REAR SEAT CUSHION ASSEMBLY LH 
    1. Install the rear seat cushion assembly LH with the 2 bolts.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

  18. INSPECT FOR FUEL LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
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