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Installation [06/2016 - 03/2017]: Procedure

  1. INSTALL NO. 1 FUEL TANK CUSHION 
    1. Install 10 new No. 1 fuel tank cushions to the fuel tank assembly.
  2. INSTALL NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Install the fuel filter to the No. 2 fuel tank main tube sub-assembly.
    2. Install the No. 2 fuel tank main tube sub-assembly to the fuel tank assembly.
  3. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel tank assembly with the clamp.
    2. Tighten the hose clamp bolt.

      Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) 

  4. INSTALL FUEL TANK ASSEMBLY 
    1. Inspect the fuel tank cover.
      GTY391657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The fuel tank cover is used as a base when attaching the fuel tank assembly, so inspect for any deformation, cracking, or other damage. If any faults are found, replace with a new one.

    2. Hold the fuel tank assembly with an engine lifter.
    3. Temporarily install the fuel tank assembly to the body with the 2 No. 1 fuel tank bands and 4 bolts.
    4. Adjust the position of the fuel tank assembly to achieve the required separation between the front edge of the fuel tank cover and the holes used for fixing the parking brake cable bracket in place.
      GTY384936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard

      42 to 44 mm (1.6535 to 1.7323 in.)

    5. Adjust the position of the fuel tank assembly to achieve the required difference in clearance between the left and right sides of the fuel tank assembly and the body.
      GTY384934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard

      Below 2 mm (0.0787 in.)

    6. Tighten the 4 bolts in the order shown in the illustration.
      GTY386826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

  5. INSTALL CHARCOAL CANISTER ASSEMBLY 
    1. Connect the quick connector as indicated by the arrows in the order shown in the illustration.
      GTY737023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Engage the clamp to install the tube.
    2. Connect the fuel tank vent hose sub-assembly with the clamp.
  7. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose to the fuel tank filler pipe sub-assembly with the clamp.
    2. Tighten the hose clamp bolt.

      Torque: 2.5 N*m (25 kgf*cm, 22 in.*lbf) 

  8. REMOVE NO. 3 PARKING BRAKE CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  9. REMOVE NO. 2 PARKING BRAKE CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  10. INSTALL NO. 3 FUEL TANK PROTECTOR 
    1. Install the No. 3 fuel tank protector with a new nut and 2 clips.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  11. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY 

    (Refer to INSTALLATION [06/2016 - 03/2017] )

  12. INSTALL FUEL TANK RETURN TUBE 

    See step  2

  13. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 

    See step  1

  14. ADD FUEL 
  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

  16. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  17. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER 

    See step  4

  18. INSTALL REAR FLOOR SERVICE HOLE COVER 

    See step  8

  19. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY LH 

    Refer to PROCEDURE - Step 18

  20. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY RH 

    Refer to PROCEDURE - Step 19

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