Fuel Tank: Installation

INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
1. Install the tank protector with the 2 nuts.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
Fig 1: Locating Tank Protector With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK CUSHION
1. Install the tank cushions and tank brackets.
Fig 2: Locating Tank Cushions And Tank Brackets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
1. Install the fuel pump tube to the 4 clamps.
INSTALL FUEL TANK SUB-ASSEMBLY
1. Set a mission jack to the fuel tank and lift it up.
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 Bands With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT EMISSION HOSE
1. Connect the 2 emission hoses.
Fig 4: Locating Emission Hoses
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CONNECT FUEL TANK TO FILLER PIPE HOSE
1. Connect the fuel tank to filler pipe hose with the clamp.
Fig 5: Locating Filler Pipe Hose With Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Connect the fuel pump tube connector.
  HINT:
  
  Push the part 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 having finished the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
Fig 6: Connecting Fuel Pump Tube Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT PARKING BRAKE CABLE ASSEMBLY
1. Connect the 4 clamps.
2. Connect the 2 parking brake cables with the 4 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) for bolt A
  
  19 N*m (193 kgf*cm, 14 ft.*lbf) for bolt B
Fig 7: Locating Parking Brake Cables With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR SUSPENSION MEMBER BRACE LH
1. Install the suspension member brace with the 4 bolts.
  Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf)
INSTALL REAR SUSPENSION MEMBER BRACE RH
1. Install the suspension member brace with the 4 bolts.
  Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf)
Fig 8: Locating Suspension Member Brace With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SIDE MEMBER COVER LH
1. Install the member cover with the 3 bolts.
Fig 9: Locating Member Cover With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SIDE MEMBER COVER RH
1. Install the member cover with the 3 bolts.
Fig 10: Locating Member Cover With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
1. Install the differential supporter with the 2 nuts.
INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
1. Install the differential supporter with the 2 nuts.
Fig 11: Locating Differential Supporter 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)
ADJUST PROPELLER W/CENTER BEARING SHAFT ASSEMBLY (See INSTALLATION )

Fig 12: Locating Tank Protector With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
1. Install the heat insulator with the 4 nuts.
Fig 13: Locating Heat Insulator With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT FLOOR COVER CENTER LH
1. Install the floor cover center with the 3 nuts.
INSTALL EXHAUST PIPE ASSEMBLY
1. Install the exhaust pipe (see DISASSEMBLY ).
Fig 14: Locating Floor Cover Center With Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  Fig 15: Setting Fuel Sender Gauge To Fuel Vent Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set the fuel return vent tube to the fuel tank.
3. Apply a light coat of gasoline to a new gasket, and set it to the fuel tank.
4. Connect the fuel tube connector, 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 tube connector, do not forcibly pull the tube.
5. Align the protrusion of the fuel suction tube and the cutout of the fuel tank.
  
  Fig 16: Aligning Protrusion Of Fuel Suction Tube And Cutout Of Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. While holding the fuel suction tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Install the fuel pump retainer to the fuel tank.
  
  Fig 17: Aligning Starting Marks Of Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a 6 mm socket wrench, 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 18: Setting SST To Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. 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 19: Tightening Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Connect the fuel main tube and pump tube.
  1. Push the fuel tube joint into the plug of the fuel suction plate, then install the tube joint clip.
10. Connect the fuel suction tube connector.
  NOTE:
  - Check that there are no scratches or foreign matter around the connected part 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 20: Locating Fuel Suction Tube Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel pump connector.
2. Install the service hole cover with new butyl tape.
  
  Fig 21: Locating Service Hole Cover With Butyl Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (See INSTALLATION )
INSTALL NO.2 REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel pump connector.
2. Install the service hole cover with new butyl tape.
Fig 22: Locating Service Hole Cover With Butyl Tape
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 3 ROOM PARTITION PAD
1. Install the partition pad with the clip.
  
  Fig 23: Identifying Partition Pad With Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR SEAT CUSHION ASSEMBLY (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHECK FOR FUEL LEAKS (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.