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Fuel Tank: Installation

  1. INSTALL FUEL TANK CUSHION 
    1. Install the 5 tank cushions and fuel tank protector.
      Fig 1: Identifying Tank Protector And Tank Cushions
      G04948105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 3 tank cushions.
      Fig 2: Identifying Fuel Tank Cushion
      G04948104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Install the vent hose to the fuel tank.
      1. Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent hose connector until the retainer makes a "click" sound to install the fuel tank vent hose to the fuel tank.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure.
        • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent hose connector.
          Fig 3: Aligning Fuel Tank Vent Hose Connector With Pipe
          G04948108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO.2 FUEL TANK PROTECTOR 
    1. Install the clamp to the fuel tank.
    2. Install the bolt and clip and fuel tank protector to the fuel tank.
      Fig 4: Identifying Fuel Tank Protector Bolt And Clip
      G04948102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Install the fuel hose clamp.
      Fig 5: Identifying Fuel Hose Clamp
      G04948101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tank main tube to the fuel tank with the 6 clamps.
      Fig 6: Locating Fuel Tank Main Tube Clamps
      G04948100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL SENDER GAUGE ASSEMBLY 
    1. Install a new gasket and sender gauge to the fuel tank with the 5 screws.

      Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

      Fig 7: Locating Fuel Sender Gauge Screws
      G04948099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
    2. Connect the fuel hose, and set the fuel suction with pump and gauge.
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • When connecting the fuel hose, do not forcibly pull the hose.
        Fig 8: Locating Fuel Hose Clamp
        G04947945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the set plate with the 8 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      HINT:

      Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.

      Fig 9: Locating Set Plate With Bolts
      G04947965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set the fuel tank on a mission jack.
    2. Raise the mission jack so that the fuel tank breather tube can be connected.

      HINT:

      Raise the mission jack slowly.

    3. Connect the fuel tank breather tube sub-assembly.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 10: Connecting Fuel Tank Breather Tube Sub-Assembly
        G04948115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the fuel vent hose.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 11: Connecting Fuel Vent Hose
        G04948116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Slowly raise the mission jack, and install the 2 fuel tank bands with the 4 bolts.

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

      NOTE:
      • Do not allow the fuel tank to contact the vehicle, especially the differential.
      • Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.
        Fig 12: Locating Fuel Tank Bands Bolts
        G04948094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the filler pipe hose to the fuel tank.
    7. Tighten the clamp.
      Fig 13: Locating Filler Pipe Hose Clamp
      G04948093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the fuel main tube.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 14: Connecting Fuel Main Tube
        G04948119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the fuel return tube.

      HINT:

      Push the parts together firmly until a "click" sound is heard.

      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
        • Fig 15: Connecting Fuel Return Tube
        G04948119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 
    1. Install the propeller with center bearing shaft (see INSTALLATION ).
  9. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Install the exhaust pipe (see INSTALLATION ).
  10. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel sender gauge connector.
      2. Fig 16: Locating Fuel Sender Gauge Connector
      G04948090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the service hole cover with new butyl tape.
  11. INSTALL FUEL TANK MAIN AND RETURN TUBE 
    Fig 17: Identifying Fuel Main Tube And Fuel Return Tube With Clips
    G04947966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the fuel main tube and fuel return tube with the 2 tube joint clips.
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting parts.
      • Check that the fuel tube joint is inserted securely.
      • Check that the tube joint clips are on the collars of the fuel tube joints.
      • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
        Fig 18: Identifying Fuel Tube Joint Correct And Incorrect Position
        G04947967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Connect the connector.
      2. Fig 19: Locating Fuel Pump Connector
      G04947835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the service hole cover with new butyl tape.
  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  14. INSTALL COWL TOP VENTILATOR LOUVER RH  (See INSTALLATION )
  15. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  16. CHECK FOR FUEL LEAKS  (See ON-VEHICLE INSPECTION  )
  17. INSTALL REAR SEAT ASSEMBLY (for Power Seat) 
    1. Install rear seat assembly (see INSTALLATION ).
  18. INSTALL REAR SEAT ASSEMBLY (for Ottoman) 
    1. Install rear seat assembly (see INSTALLATION ).
  19. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Type) 
    1. Install rear seat cushion assembly (see INSTALLATION ).
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