Fuel Tank: Installation: Installation

INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
1. Install the tank protector with the 2 nuts.
  
  Fig 1: Locating Nuts On Fuel Tank Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.0 N*m ( 51 kgf*cm, 44 in.*lbf)
INSTALL FUEL TANK CUSHION
1. Install the tank cushions and tank brackets.
  
  Fig 2: Locating Tank Cushions And Fuel Tank Brackets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
1. Install the fuel tank return vent tube and the fuel pump tube to the 2 clamps.
  
  Fig 3: Locating Fuel Pump Tube Sub-Assembly Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK SUB-ASSEMBLY
1. Set an engine lifter to the fuel tank and lift it up.
2. Install the 2 fuel tank bands with the 4 bolts to install the fuel tank.
  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)
CONNECT FUEL EMISSION HOSE
1. Connect the 2 fuel emission hoses.
  
  Fig 4: Locating Fuel Emission Hoses And Fuel Tank Bracket Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the fuel tank bracket hose.
CONNECT FUEL TANK TO FILLER PIPE HOSE

Fig 5: Identifying Filler Pipe Hose From Fuel Tank Filler Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Connect the fuel tank to filler pipe hose with the clamp.
CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (for LH Side)
1. Connect the fuel pump tube connector.
  1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
    
    Fig 6: Pushing Up Retainer To Engage Claws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Check for damage or foreign objects on the connected part.
    
    After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
CONNECT FUEL TANK RETURN VENT TUBE
1. Connect the fuel tank return vent tube connector.
  1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
    
    Fig 7: Pushing Fuel Tube Connector To Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Check for damage or foreign objects on the connected part.
    
    After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
CONNECT FUEL PUMP TUBE SUB-ASSEMBLY (for RH Side)
1. Connect the fuel pump tube connector.
  1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
    
    Fig 8: Connecting Fuel Pump Tube Sub-Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    Check for damage or foreign objects on the connected part.
    
    After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
CONNECT PARKING BRAKE CABLE ASSEMBLY
1. Connect the 4 clamps.
  
  Fig 9: Identifying Parking Brake Cables With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 2 parking brake cables with the 4 bolts.
  bolt A
  
  Torque: 6.0 N*m ( 61 kgf*cm, 53 in.*lbf)
  
  bolt B
  
  Torque: 19 N*m ( 193 kgf*cm, 14 ft.*lbf)
INSTALL REAR SUSPENSION MEMBER BRACE REAR LOWER LH . Refer to REPLACEMENT - Step 30
INSTALL REAR SUSPENSION MEMBER BRACE REAR LOWER RH . Refer to REPLACEMENT - Step 31
INSTALL REAR FLOOR SIDE MEMBER COVER LH . Refer to REPLACEMENT - Step 33
INSTALL REAR FLOOR SIDE MEMBER COVER RH . Refer to REPLACEMENT - Step 34
INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR

Fig 10: Locating Differential Support Protector Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
INSTALL NO. 2 FUEL TANK PROTECTOR

Fig 11: Locating Fuel Tank Protector Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the tank protector with the 4 nuts.
  Torque: 5.0 N*m ( 51 kgf*cm, 44 in.*lbf)
INSTALL REAR PROPELLER SHAFT ASSEMBLY
1. Install the rear propeller shaft assembly Refer to 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.
    
    Fig 12: Setting Fuel Sender Gauge To Fuel Vent Tube
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Connect the fuel sender gauge connector.
2. Set the fuel return vent tube to the fuel tank.
  
  Fig 13: Aligning Protrusion Of Fuel Suction Tube And Cutout Of Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply a light coat of gasoline to a new fuel suction tube set gasket, and set it to the fuel tank.
4. Connect the fuel tube connector, and set the fuel suction with pump and gauge tube.
  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.
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 14: Aligning Starting Marks Of New Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a 6 mm socket, set SST to the fuel pump gauge retainer.
  
  Fig 15: Setting SST To Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST: 09808-14020 (09808-01410 ,09808-01420 ,09808-01430)
  
  NOTE:
  Do not use any other tools such as a screwdriver.
  
  HINT:
  
  Fit the tips of SST on the ribs of the retainer.
8. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the start mark on the retainer is within the indicated range in the illustration.
  
  Fig 16: Tightening Fuel Pump Gauge Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel sender gauge connector.
  
  Fig 17: Locating Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the service hole cover with new butyl tape.
INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE See step 1
INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER See step 4
INSTALL ROOM NO. 3 PARTITION PAD See step 5
INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 4
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Refer to INITIALIZATION .