Fuel Tank: Installation

INSTALL NO. 1 FUEL TANK PROTECTOR
1. Install the tank protector with the 2 nuts.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
Fig 1: Locating Nuts On Fuel Tank Protector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK CUSHION
1. Install the tank cushions and tank brackets.
INSTALL FUEL RETURN TUBE

Fig 2: Locating Tank Cushions And Fuel Tank Brackets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Attach the fuel tank main tube to the clamps, and install it.
INSTALL FUEL TANK SUB-ASSEMBLY
1. Set the fuel tank on a mission jack, and raise the fuel tank.
2. Install the 2 fuel tank bands with the 4 bolts.
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
3. Install the 2 nuts.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
Fig 3: Locating Fuel Tank Main Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL EMISSION HOSE
1. Connect the 2 emission hoses.
2. Connect the fuel tank bracket hose.
Fig 4: Locating Fuel Tank Hose With Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK TO FILLER PIPE HOSE
1. Tighten the clamp and connect the fuel tank to filler pipe hose.
Fig 5: Locating Filler Pipe Hose Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 connection, check if the connectors and pipes are securely connected by trying to pull them apart.
  Fig 6: Connecting Fuel Tank Main Tube LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the fuel tank main tube RH.
  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 7: Connecting Fuel Tank Main Tube RH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL RETURN TUBE
1. Connect the fuel return tube and install the retainer.
Fig 8: Connecting Fuel Return Tube
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CONNECT PARKING BRAKE CABLE ASSEMBLY
1. Connect the 4 clamps.
2. Connect the 2 parking brake cables with the 4 bolts.
  Torque: Bolt A
  
  6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Bolt B
  
  19 N*m (193 kgf*cm, 14 ft.*lbf)
Fig 9: Connecting Parking Brake Cables With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SIDE MEMBER COVER LH
1. Install the member cover with the 2 bolts.
Fig 10: Locating Rear Floor Side Member Cover LH With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SIDE MEMBER COVER RH
1. Install the member cover with the 2 bolts.
Fig 11: Locating Rear Floor Side Member Cover RH With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
1. Install the differential support protector with the 2 nuts.
INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
1. Install the differential support protector with the 2 nuts.
Fig 12: Locating No. 2 Differential Support Protector With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 FUEL TANK PROTECTOR
1. Install the tank protector with the 4 nuts.
  Torque: 5.0 N*m (51 kgf*cm, 48 in.*lbf)
Fig 13: Locating Tank Protector With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 4WD) (See INSTALLATION )
INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 2WD) (See INSTALLATION )
INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 4WD) (See INSTALLATION )
INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 2WD) (See INSTALLATION )
INSTALL AIR GUIDE PLATE OUTSIDE RH (See INSTALLATION )
INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
1. Install the heat insulator with the 4 nuts.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
Fig 14: Locating Front Floor No. 1 Heat Insulator With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT FLOOR COVER CENTER RH
1. Attach the 2 clips, and install the floor cover center with the 3 nuts.
  
  Fig 15: Locating Front Floor Cover Center Nuts And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST PIPE ASSEMBLY
1. Install the exhaust pipe (see INSTALLATION ).
INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY
1. Install the fuel sender gauge.
  1. Set the fuel sender gauge to the fuel vent tube. Then slide the sender gauge downward to install it.
  2. Connect the fuel sender gauge connector.
2. Apply a light coat of gasoline to a new gasket, and set it to the fuel tank.
  
  Fig 16: Pressing Sender Gauge Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Set the fuel return vent tube sub-assembly to the fuel tank as shown in the illustration.
  NOTE:
  - Be careful not to bend the arm of the fuel sender gauge.
4. Align the protrusion of the fuel return vent tube sub-assembly and the cutout of the fuel tank.
  
  Fig 17: Aligning Protrusion Of Fuel Return Vent Tube Sub-Assembly And Cutout Of Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. While holding the fuel tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Then install the fuel pump gauge retainer to the fuel tank.
  
  Fig 18: Aligning Starting Marks Of Fuel Pump Gauge Retainer And Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
  SST 09808-14020
  
  HINT:
  
  Fit the tips of SST on the ribs of the retainer.
  
  NOTE: Use SST. Do not any other tools such as a screwdriver.
  
  Fig 19: Identifying SST On Ribs Of Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the starting mark on the retainer is within the indicated range in the illustration.
  
  Fig 20: Tightening Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Connect the fuel return tube.
  1. Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
    NOTE:
    Check that there are no scratches or foreign matter around the connected parts of the fuel tube joint and plug before performing this work.
    
    Check that the fuel tube joint is securely inserted.
    
    Check that the tube joint clip is on the collar of the fuel tube joint.
    
    After installing the tube joint clip, check that the fuel tube cannot be pulled out.
Fig 21: Locating Fuel Return Tube Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel sender gauge connector.
2. Install the service hole cover with new butyl tape.
Fig 22: Locating Service Hole Cover Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY (See INSTALLATION )
INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER (See INSTALLATION )
INSTALL ROOM NO. 3 PARTITION PAD (See INSTALLATION )
INSTALL REAR SEAT CUSHION ASSEMBLY (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSPECT FOR FUEL LEAK (See ON-VEHICLE INSPECTION )
INSPECT FOR EXHAUST GAS LEAK (See INSTALLATION )
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.