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Fuel Tank: Installation: Installation

  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR 
    1. Install the No. 1 fuel tank heat insulator with the 4 clips.
      Fig 1: Locating Fuel Tank Heat Insulator With Clips
      GTY148567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.
  2. INSTALL FUEL TANK TO FILLER PIPE HOSE 
      Fig 2: Identifying Fuel Tank Mark Location
      GTY132066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the fuel tank to filler pipe hose to the fuel tank as shown in the illustration.

      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 3: Identifying Hose Clamp
        GTY132345Courtesy 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.
    2. Install the fuel suction with pump and gauge tube into the fuel tank.
      Fig 4: Aligning Protrusion Of Fuel Suction With Groove Of Fuel Tank
      GTY148583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • Align the protrusion of the fuel suction with 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.
    4. Set SST on the fuel pump gauge retainer.
      • SST: 09808-14030 
      Fig 5: Identifying SST On The Fuel Pump Gauge Retainer
      GTY292186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.
      • Securely attach the claws of SST to the protrusions of the fuel pump gauge retainer and fix SST in place.
      • Install SST while pressing the claws of SST against the fuel pump gauge retainer (toward the center of SST).
    5. 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: 09808-14030 
      Fig 6: Identifying SST & Ribs Of The Retainer
      GTY291158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  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 7: Locating Fuel Tank Tubes Clips
      GTY137614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 8: Identifying Fuel Tube Joints Correct And Incorrect Position
      GTY145817Courtesy 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.
    2. Install the fuel tank main tube and fuel tank return tube to the fuel tank.
      Fig 9: Locating Fuel Main Tube And Fuel Return Tube
      GTY122458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    3. Install the 2 fuel tank bands with the 2 pins and 2 clips.
      Fig 10: Locating Bolts, Clips, Pins And Fuel Tank Bands
      GTY128939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 2 fuel tank bands with the 2 bolts.

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

  6. CONNECT FUEL TANK TO FILLER PIPE HOSE 
      Fig 11: Identifying Distance Between Fuel Tank Inlet Pipe And Fuel Tank
      GTY224701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the fuel tank to filler pipe hose to the fuel tank filler pipe as shown in the illustration.

      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.
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
        Fig 12: Identifying Hose Clamp
        GTY132345Courtesy 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.
      Fig 13: Locating Fuel Tank Breather Tube
      GTY238066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
  8. CONNECT NO. 2 FUEL TANK TANK BREATHER TUBE SUB-ASSEMBLY 
    1. Connect the No. 2 fuel tank breather tube.
      Fig 14: Locating Fuel Tank Breather Tube
      GTY238065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  9. CONNECT FUEL TANK RETURN TUBE 
    1. Connect the fuel tank return tube.
      Fig 15: Connecting Fuel Tank Return Tube
      GTY148562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
  10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube.
      Fig 16: Connecting Fuel Tank Main Tube
      GTY148563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
  11. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
      Fig 17: Locating Fuel Tank Protector Bolts
      GTY148560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the tank protector with the 5 bolts.

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

  12. INSTALL FUEL TANK CAP ASSEMBLY 
  13. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
      Fig 18: Locating Fuel Pump And Fuel Sender Gauge Connector
      GTY134692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the fuel pump and fuel sender gauge connector.
      2. Fig 19: Identifying Service Hole Cover
      GTY137671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the service hole cover with new butyl tape.
      3. Fig 20: Locating Air Duct Screws
      GTY137816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the air duct with the 2 screws.
  14. INSTALL FRONT FLOOR CARPET ASSEMBLY  . Refer to INSTALLATION - Step 3
  15. INSTALL REAR AIR DUCT GUIDE  . Refer to INSTALLATION - Step 10
  16. INSTALL AIR DUCT PLUG  . Refer to INSTALLATION - Step 11
  17. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH  . Refer to INSTALLATION - Step 58
  18. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH  . Refer to INSTALLATION - Step 57
  19. INSTALL LUGGAGE COMPARTMENT NO. 1 TRIM HOOK  . Refer to INSTALLATION - Step 60
  20. INSTALL REAR FLOOR MAT REAR SUPPORT PLATE  . Refer to INSTALLATION - Step 71
  21. INSTALL REAR NO. 2 SEAT ASSEMBLY 
    1. Install the rear No. 2 seat assembly, refer to INSTALLATION .
  22. INSTALL REAR DOOR SCUFF PLATE RH  . Refer to INSTALLATION - Step 76
  23. INSTALL REAR DOOR SCUFF PLATE LH  . Refer to INSTALLATION - Step 72
  24. INSTALL REAR STEP COVER  . Refer to INSTALLATION - Step 74
  25. INSTALL REAR NO. 2 SEAT PROTECTOR  . Refer to INSTALLATION - Step 15
  26. INSTALL REAR NO. 1 SEAT PROTECTOR  . Refer to INSTALLATION - Step 16
  27. INSTALL REAR NO. 1 SEAT ASSEMBLY RH 
    1. Install the rear No. 1 seat assembly, refer to INSTALLATION .
  28. INSTALL REAR NO. 1 SEAT ASSEMBLY LH 
    1. Install the rear No. 1 seat assembly, refer to INSTALLATION .
  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  30. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light, refer to DIAGNOSIS SYSTEM .
  31. ADD FUEL 
  32. INSPECT FOR FUEL LEAK  See step  12
  33. INSPECT REAR NO. 1 SEAT ASSEMBLY RH  . Refer to INSTALLATION - Step 25
  34. INSPECT REAR NO. 1 SEAT ASSEMBLY LH  . Refer to INSTALLATION - Step 25
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