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Fuel Tank: Installation

  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR 
    1. Install the No. 1 fuel tank heat insulator with the 4 clips.
    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.
    Fig 1: Locating Fuel Tank Heat Insulator With Clips
    G05628908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose to the fuel tank as shown in the illustration (Fig 2).

      HINT:

      • Align the fuel tank side mark with the hose side mark when installing the hose.
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration (Fig 2).
      Fig 2: Identifying Fuel Tank Mark Location
      G05628909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 it to the fuel tank.
      Fig 3: Identifying Hose Clamp
      G05628910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel suction with pump and gauge tube into the fuel tank.
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • Align the protrusion of the pump and gauge tube with the groove of the fuel tank.
    3. Put the retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer 1 complete turn by hand.
      Fig 4: Aligning Protrusion Of Pump And Gauge Tube With Groove Of Fuel Tank
      G05628911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 (Fig 5).

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      HINT:

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

      Fig 5: Fitting Tips Of SST Onto Ribs Of Retainer
      G05628912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY 
    1. Install the 2 fuel tank tubes and No. 1 fuel tube joint with the 3 tube joint clips.
      Fig 6: Locating Fuel Tank Tubes Clips
      G05628913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting parts.
      • Check that the fuel tube joints are 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 7: Identifying Fuel Tube Joints Correct And Incorrect Position
      G05628914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tank main tube and fuel tank return tube to the fuel tank.
  5. INSTALL FUEL TANK SUB-ASSEMBLY 
    1. Set the fuel tank on a transmission jack and raise the fuel tank.
    2. Raise the transmission jack.
      Fig 8: Locating Fuel Main Tube And Fuel Return Tube
      G05628904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 fuel tank bands with the 2 pins and 2 clips.
    4. Connect the 2 fuel tank bands with the 2 bolts.

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

      Fig 9: Locating Bolts, Clips, Pins And Fuel Tank Bands
      G05628902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the fuel tank to filler pipe hose to the fuel tank filler pipe as shown in the illustration (Fig 10).

      HINT:

      • Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration (Fig 10).
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration (Fig 11).
      Fig 10: Identifying Distance Between Fuel Tank Inlet Pipe And Fuel Tank
      G05628917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 11: Identifying Hose Clamp
      G05628910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank breather tube to the fuel tank filler pipe.

      HINT:

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
    Fig 12: Locating Fuel Tank Breather Tube
    G05628919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT NO. 2 FUEL TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the No. 2 fuel tank breather tube.
      NOTE:
      • Before installing the hose, make sure that it is not damaged. Make sure that there is no foreign matter present on the connecting surfaces.
      • After connecting, check if the hose and the connector are securely connected by pulling on them.
    2. Attach the 2 fuel tube clamps.
    Fig 13: Locating Fuel Tank Breather Tube
    G05628920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT FUEL TANK RETURN TUBE 
    1. Connect the fuel tank return tube.

      HINT:

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
    Fig 14: Connecting Fuel Tank Return Tube
    G05628921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube.

      HINT:

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
    Fig 15: Connecting Fuel Tank Main Tube
    G05628922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the tank protector with the 5 bolts.

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

      Fig 16: Locating Fuel Tank Protector Bolts
      G05628891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FUEL TANK CAP ASSEMBLY 
  13. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. Connect the fuel pump and fuel sender gauge connector.
      Fig 17: Locating Fuel Sender Gauge Connector
      G05628897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the service hole cover with new butyl tape.
      Fig 18: Identifying Service Hole Cover
      G05628896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the air duct with the 2 screws.
  14. INSTALL FRONT FLOOR CARPET ASSEMBLY  (See INSTALLATION )
  15. INSTALL REAR AIR DUCT GUIDE  (See INSTALLATION )
  16. INSTALL AIR DUCT PLUG  (See INSTALLATION )
    Fig 19: Locating Air Duct Screws
    G05628895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH  (See INSTALLATION )
  18. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH  (See INSTALLATION )
  19. INSTALL LUGGAGE COMPARTMENT NO. 1 TRIM HOOK  (See INSTALLATION )
  20. INSTALL REAR FLOOR MAT REAR SUPPORT PLATE  (See INSTALLATION )
  21. INSTALL REAR NO. 2 SEAT ASSEMBLY 
    1. Install the rear No. 2 seat assembly (See INSTALLATION ).
  22. INSTALL REAR DOOR SCUFF PLATE RH  (See INSTALLATION )
  23. INSTALL REAR DOOR SCUFF PLATE LH  (See INSTALLATION )
  24. INSTALL REAR STEP COVER  (See INSTALLATION )
  25. INSTALL REAR NO. 2 SEAT PROTECTOR  (See INSTALLATION )
  26. INSTALL REAR NO. 1 SEAT PROTECTOR  (See INSTALLATION )
  27. INSTALL REAR NO. 1 SEAT ASSEMBLY RH 
    1. Install the rear No. 1 seat assembly (See INSTALLATION ).
  28. INSTALL REAR NO. 1 SEAT ASSEMBLY LH 
    1. Install the rear No. 1 seat assembly (See INSTALLATION ).
  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  30. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (See DIAGNOSIS SYSTEM ).
  31. ADD FUEL 
  32. INSPECT FOR FUEL LEAK  (See INSTALLATION  )
  33. INSPECT REAR NO. 1 SEAT ASSEMBLY RH  (See INSTALLATION )
  34. INSPECT REAR NO. 1 SEAT ASSEMBLY LH  (See INSTALLATION )
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