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Installation [08/2015 - ]: Procedure

  1. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel tank.
      GTY724598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Fuel Tank Side Mark
      *2 Hose Side Mark

      HINT: 

      Align the fuel tank side mark with the hose side mark when installing the hose.

  2. INSTALL NO. 3 FUEL TANK PROTECTOR 
    1. Install the No. 3 fuel tank protector and attach the 4 clamps.
      GTY266801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 bolts.

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

  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank.
    2. Install the fuel suction with pump and gauge tube into the fuel tank.
      GTY720196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protrusion
      *2 Groove

      HINT: 

      Align the protrusion of the fuel suction with pump and gauge tube with the groove of the fuel tank.

      NOTE:

      Be careful not to bend the arm of the fuel sender gauge.

    3. Put the new retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer one complete turn by hand.
    4. Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank, as shown in the illustration.
      • SST: 09808-14020 
      GTY266225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Fuel Tank Side Mark
      *2 Retainer Side Mark

      HINT: 

      Fit the tips of SST onto the ribs of the retainer.

  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY 
    1. Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.
      GTY284460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting parts.
        GTY263657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Check that the fuel tube joints are inserted securely.
      • Check that the fuel tube joint clips are on the collars of the fuel tube joints.
      • After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.
        TEXT IN ILLUSTRATION

        *1 Fuel Tube Joint
        *2 O-Ring
        *3 Fuel Tube
        *4 Fuel Tube Joint Clip
        *a CORRECT
        *b INCORRECT
    2. Install the fuel tank main tube and fuel return tube to the fuel tank.
      GTY269444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Install the fuel tank breather tube (Refer to PRECAUTION [08/2015 - ] ).
      GTY256039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the fuel tank protector to the fuel tank.
      GTY262058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL TANK CUSHION 
    1. Install 3 new fuel tank cushions to the fuel tank.
      GTY260225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion
      *3 No. 3 Fuel Tank Cushion
  8. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set the fuel tank on a transmission jack and lift up the transmission jack.
      NOTE:

      Do not allow the fuel tank to contact the vehicle, especially the differential.

    2. Install the 2 fuel tank bands with the 2 pins and 2 clips.
      GTY266792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 fuel tank bands with the 2 bolts.

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

  9. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose to the filler pipe.
  10. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank breather tube (Refer to PRECAUTION [08/2015 - ] ).
  11. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Connect the fuel tank breather tube (Refer to PRECAUTION [08/2015 - ] ).
      GTY269445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY 
    1. Connect the fuel return tube (Refer to PRECAUTION [08/2015 - ] ).
      GTY275942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube (Refer to PRECAUTION [08/2015 - ] ).
      GTY266830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. for Half Cover Type:

      Install the No. 1 fuel tank protector with the 4 bolts.

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

    2. for Standard Type:

      Install the No. 1 fuel tank protector with the 6 bolts.

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

  15. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel pump and fuel sender gauge connector.
    2. Install the rear floor service hole cover with the 3 screws.
  16. INSTALL REAR SEAT ASSEMBLY LH 
    1. for 60/40 Split Double-folding Seat Type LH Side:

      Install the rear seat assembly LH (Refer to INSTALLATION [08/2015 - ] ).

    2. for 60/40 Split Slide Walk-in Seat Type LH Side:

      Install the rear seat assembly LH (Refer to INSTALLATION [08/2015 - ] ).

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [08/2015 - 08/2019] , or refer to INITIALIZATION [08/2019 - 08/2022] , or refer to INITIALIZATION [08/2022 - ] ).

  18. INSPECT FOR FUEL LEAK 

    See step  7

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