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Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the fuel tank protector to the fuel tank.
  2. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Install the fuel tube 6 clamps.
    2. Install the fuel tank main tube to the fuel tank with the 6 clamps
      Fig 1: Locating Fuel Tank Protector And Clamps
      G05773060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL TANK RETURN VENT TUBE 
    1. Install the fuel tank return vent tube to the fuel tank.
      Fig 2: Locating Fuel Tank Return Vent Tube
      G05773059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Install the vent hose to the fuel tank.
      NOTE:
      • Check for damage or foreign matter around the connecting parts of the vent hose and fuel tank.
      • After connecting, check that the vent hose and the valve are securely connected by pulling on them.
        Fig 3: Locating Vent Hose To Fuel Tank
        G05773063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Install the fuel suction 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 connecting, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 4: Installing Fuel Suction Tube Sub-Assembly
        G05773064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL TANK WIRE 
    1. Attach the 6 clamps of the fuel tank wire to install the wire to the fuel tank
      2. Fig 5: Identifying Fuel Tank Wire Clamps
      G05773056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL TANK PRESSURE SENSOR 
    1. Install the fuel tank pressure sensor (see INSTALLATION ).
  8. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank on a mission jack and raise the fuel tank.
      NOTE: Do not allow the fuel tank to contact the vehicle, especially the differential.
    2. Connect the fuel tank to the fuel filler pipe and slide the filler pipe clamp.
      Fig 6: Locating Filler Pipe Clamp
      G05773066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Insert the filler pipe into the fuel tank with their axes aligned. If not aligned, the insertion load increases.
      • Do not twist or forcefully insert the filler pipe.
      • After securely inserting the filler pipe into the fuel tank, attach the clamp. At this time, securely insert the clamp into the slit.
        Fig 7: Identifying Fuel Filler Pipe And Fuel Tank
        G05303320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the 2 fuel tank bands with the 4 bolts
    4. Tighten the bolts in the front

      Torque: 39 N*m (408 kgf*cm, 30 ft.*lbf) 

      Fig 8: Locating Fuel Tank Assembly Bolts
      G05773054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, a torque wrench and union nut wrench, tighten the bolts in the rear.

      SST 09961-00950 

      Torque: without SST 

      39 N*m (408 kgf*cm, 30 ft.*lbf) 

      with SST 

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

      HINT:

      • Use a torque wrench with a fulcrum length of 180 mm (7.09 in).
      • Make sure union nut wrench, SST and torque wrench are connected in a straight line.
        Fig 9: Identifying Fulcrum Length
        G05773069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT FUEL TANK WIRE 
    1. Connect the fuel vapor containment valve connector and attach the 2 clamps.
      Fig 10: Locating Fuel Tank Wire Clamps
      G05773053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Connect the fuel suction 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 connecting, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 11: Locating Fuel Suction Tube Sub-Assembly
        G05773071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Connect the fuel tank vent hose.

      HINT

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

      NOTE:
      • Before installing the hose connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 12: Locating Fuel Tank Vent Hose And Retainer
        G05773072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. CONNECT FUEL TANK RETURN VENT TUBE 
    1. Connect the fuel tank return vent 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 connecting, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 13: Identifying Fuel Tank Return Vent Tube
        G05773073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube LH.

      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 connecting, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 14: Identifying Fuel Tank Main Tube Sub-Assembly
        G05773074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the fuel tank main tube RH. HI NT-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 connecting, check if the connectors and pipes are securely connected by trying to pull them apart.
        Fig 15: Locating Fuel Tank Main Tube Sub-Assembly And Retainer
        G05773075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FUEL TANK PROTECTOR BRACKET SIDE 
    1. Install the protector with the 2 nuts

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

      Fig 16: Locating Tank Protector And Clip
      G05773047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FUEL TANK FILLER PIPE PROTECTOR 
    1. Install the tank protector with the 2 clips and 2 nuts.

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

      Fig 17: Locating Tank Protector And Clip
      G05773046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 
    1. Install the propeller with center bearing shaft (see INSTALLATION )
  17. 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 install the fuel suction with pump and gauge tube to the fuel tank.
      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 18: Locating Fuel Hose Clamp
        G05773078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the No 2 fuel tank protector and 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 with pump and gauge tube.

      Fig 19: Locating Fuel Tank Vent Tube Set Plate
      G05773079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips.
      Fig 20: Locating Fuel Tank Return Vent Tube With Tube Joint Clips
      G05773080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 21: Identifying Fuel Tube Joint And Clip Location
        G04947967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Connect the 2 connectors.
    2. Install the service hole cover with new butyl tape
      Fig 22: Locating Rear Floor No. 2 Service Hole Cover And Connectors
      G05773082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FUEL SENDER GAUGE ASSEMBLY 
    1. Install a new gasket and the sender gauge to the fuel tank with the 5 screws.

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

      Fig 23: Locating Fuel Sender Gauge Assembly Bolts
      G05773045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL REAR FLOOR SERVICE HOLE COVER 
    1. Connect the fuel sender gauge connector.
    2. Install the service hole cover with new butyl tape.
      3. Fig 24: Locating Rear Floor Service Hole Cover
      G05773044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL REAR NO. 2 SEAT ADJUSTER ASSEMBLY (for Power Seat) 
    1. Install the rear No. 2 seat adjuster assembly (see INSTALLATION ).
  23. INSTALL REAR NO. 2 SEAT ADJUSTER ASSEMBLY (for Ottoman) 
    1. Install the rear No. 2 seat adjuster assembly (see INSTALLATION ).
  24. INSTALL REAR NO. 1 SEAT ADJUSTER ASSEMBLY (for Power Seat) 
    1. Install the rear No. 1 seat adjuster assembly (see INSTALLATION )
  25. INSTALL REAR NO. 1 SEAT ADJUSTER ASSEMBLY (for Ottoman) 
    1. Install the rear No 1 seat adjuster assembly (see INSTALLATION )
  26. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)  (See INSTALLATION )
  27. INSTALL SERVICE PLUG GRIP  (See INSPECTION )
  28. INSTALL BATTERY SERVICE HOLE COVER  (See INSTALLATION )
  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  30. INSTALL BATTERY SERVICE HOLE COVER LH  (See INSTALLATION )
  31. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY  (See INSTALLATION )
  32. ADD FUEL 
  33. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION  )
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