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Fuel Tank: Installation: Installation

  1. INSTALL NO. 1 FUEL TANK PROTECTOR 
    Fig 1: Identifying Nuts On Fuel Tank Protector
    GTY103789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the tank protector with the 2 nuts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  2. INSTALL FUEL TANK CUSHION 
    Fig 2: Identifying Tank Cushions And Fuel Tank Brackets
    GTY103479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the tank cushions and tank brackets.
  3. INSTALL FUEL RETURN TUBE 
  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    Fig 3: Identifying Fuel Tank Main Tube
    GTY102073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Attach the fuel tank main tube to the clamps, and install it.
  5. 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) 

  6. CONNECT FUEL EMISSION HOSE 
    Fig 4: Identifying Fuel Emission Hoses And Fuel Tank Bracket Hose
    GTY104756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the 2 emission hoses.
    2. Connect the fuel tank bracket hose.
  7. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    Fig 5: Identifying Filler Pipe Hose And Clamp
    GTY104551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Tighten the clamp and connect the fuel tank to filler pipe hose.
  8. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
      Fig 6: View Of Connecting Fuel Tank Main Tube LH
      GTY105387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    1. Connect the fuel tank main tube LH.

      HINT: 

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

      2. Fig 7: View Of Connecting Fuel Tank Main Tube RH
      GTY100153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. Connect the fuel tank main tube RH.

      HINT: 

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

  9. CONNECT FUEL RETURN TUBE 
    Fig 8: View Of Connecting Fuel Return Tube
    GTY103878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the fuel return tube and install the retainer.
  10. CONNECT PARKING BRAKE CABLE ASSEMBLY 
    Fig 9: Identifying Parking Brake Cables With Bolts
    GTY104624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the 4 clamps.
    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) 

  11. INSTALL REAR FLOOR SIDE MEMBER COVER LH 
    Fig 10: Identifying Member Cover Bolts
    GTY100436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the member cover with the 2 bolts.
  12. INSTALL REAR FLOOR SIDE MEMBER COVER RH 
    Fig 11: Identifying Member Cover Bolts
    GTY100719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the member cover with the 2 bolts.
  13. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR 
    Fig 12: Identifying Differential Support Protector Nuts
    GTY103975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the differential support protector with the 2 nuts.
  14. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR 
    1. Install the differential support protector with the 2 nuts.
  15. INSTALL NO. 2 FUEL TANK PROTECTOR 
    Fig 13: Identifying Fuel Tank Protector Nuts
    GTY104622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the tank protector with the 4 nuts.

      Torque: 5.0 N*m (51 kgf*cm, 48 in.*lbf) 

  16. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 4WD)  . Refer to INSTALLATION - Step 1
  17. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 2WD)  . Refer to INSTALLATION - Step 1
  18. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 4WD)  . Refer to INSTALLATION - Step 2
  19. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 2WD)  . Refer to INSTALLATION - Step 4
  20. INSTALL AIR GUIDE PLATE OUTSIDE RH  . Refer to INSTALLATION - Step 6
  21. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR 
    Fig 14: Identifying Heat Insulator Nuts
    GTY103582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the heat insulator with the 4 nuts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  22. INSTALL FRONT FLOOR COVER CENTER RH 
    Fig 15: Identifying Front Floor Cover Center Nuts And Clips
    GTY104745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Attach the 2 clips, and install the floor cover center with the 3 nuts.
  23. INSTALL EXHAUST PIPE ASSEMBLY 
    1. Install the exhaust pipe. Refer to INSTALLATION .
  24. INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY 
      Fig 16: View Of Pressing Sender Gauge Claw
      GTY102163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      3. Fig 17: View Of Aligning Protrusion Of Fuel Return Vent Tube Sub-Assembly And Cutout Of Fuel Tank
      GTY105462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
    3. Set the fuel return vent tube sub-assembly to the fuel tank as shown in the illustration.
    4. Align the protrusion of the fuel return vent tube sub-assembly and the cutout of the fuel tank.
      5. Fig 18: View Of Aligning Starting Marks Of Fuel Pump Gauge Retainer And Fuel Tank
      GTY103207Courtesy 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.
      6. Fig 19: Identifying SST On Ribs Of Retainer
      GTY104552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Use SST. Do not any other tools such as a screwdriver.

    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.

      7. Fig 20: View Of Tightening Fuel Pump Gauge Retainer
      GTY102753Courtesy 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.
      8. Fig 21: Identifying Fuel Return Tube Connector
      GTY105386Courtesy 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.
  25. INSTALL REAR FLOOR SERVICE HOLE COVER 
    Fig 22: Identifying Service Hole Cover And Fuel Sender Gauge Connector
    GTY105385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the fuel sender gauge connector.
    2. Install the service hole cover with new butyl tape.
  26. INSTALL FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY  See step  8
  27. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER  See step  11
  28. INSTALL ROOM NO. 3 PARTITION PAD  See step  12
  29. INSTALL REAR SEAT CUSHION ASSEMBLY  . Refer to INSTALLATION - Step 4
  30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  31. INSPECT FOR FUEL LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  32. INSPECT FOR EXHAUST GAS LEAK  . Refer to INSTALLATION - Step 9
  33. PERFORM INITIALIZATION 
    1. Perform initialization. Refer to INITIALIZATION .
      NOTE:

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

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