Fuel Tank: Installation: Installation

INSTALL FUEL TANK CUSHION
1. Install the tank cushion and tank protector.
  
  Fig 1: Identifying Tank Cushion And Tank Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 11 tank cushions.
  
  Fig 2: Identifying Fuel Tank Cushions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY
1. Install the vent hose to the fuel tank.
  
  Fig 3: Identifying Vent Hose To Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Attach the 2 claws to the claw holes and install a new edge protector.
  
  Fig 4: Attaching Claws To Claw Holes
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the clamp, fuel tank main tube and return tube.
  
  Fig 5: Locating Clamp, Fuel Tank Main Tube And Return Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY
1. Install a new gasket and the canister tube with the 4 screws.
  
  Fig 6: Locating Canister Tube And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
INSTALL FUEL TANK WIRE
1. Install the tank wire with the 7 clamps.
  
  Fig 7: Locating Clamps And Tank Wire From Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL TANK VENT TUBE SET PLATE . Refer to INSTALLATION - Step 1
INSTALL FUEL TANK PRESSURE SENSOR . Refer to INSTALLATION - Step 2
INSTALL NO. 3 FUEL TANK PROTECTOR . Refer to INSTALLATION - Step 3
INSTALL FUEL TANK SUB-ASSEMBLY
1. Set the fuel tank on a mission jack and raise the fuel tank.
2. Install the clamp, and connect the fuel filler pipe to the fuel tank.
  
  Fig 8: Identifying Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  Fig 9: Identifying Filler Pipe Into Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Insert the filler pipe into the fuel tank with their axes aligned. If not aligned, the insertion load increases.
  - Do not twist or forcefully insert the filler pipe.
  - After securely inserting the filler pipe into the fuel tank, attach the clamp. At this time, securely insert the clamp into the slit.
3. Raise the mission jack.
4. Install the 2 fuel tank bands with the 4 bolts.
  
  Fig 10: Identifying Bolts, Fuel Tank Bands And Fuel Tank Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
5. Tighten the 2 fuel filler pipe bolts.
  
  Fig 11: Locating Fuel Filler Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
CONNECT FUEL TANK WIRE
1. Connect the fuel vapor containment valve connector and 2 clamps.
  
  Fig 12: Locating Fuel Vapor Containment Valve Connector And Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY
1. Connect the canister tube and install the clamp.
  
  Fig 13: Connecting Fuel Tank To Canister Tube Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY
1. Connect the fuel tank vent hose and install the clamp.
  
  Fig 14: Locating Fuel Tank Vent Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Connect the fuel tank main tube (LH).
  
  Fig 15: Connecting Fuel Tank Main Tube (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
2. Connect the fuel tank main tube (RH).
  
  Fig 16: Connecting Fuel Tank Main Tube (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
CONNECT FUEL TANK RETURN VENT TUBE
1. Connect the fuel return vent tube and install the retainer.
  
  Fig 17: Connecting Fuel Return Vent Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
CONNECT PARKING BRAKE CABLE ASSEMBLY
1. Connect the 2 parking brake cables to the parking brake equalizer.
  
  Fig 18: Connecting Parking Brake Cables With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 parking brake cables with the 4 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  for bolt A
  
  Torque: 19 N*m (193 kgf*cm, 14 ft.*lbf)
  
  for bolt B
3. Attach the 2 parking brake cables to the 4 clamps.
INSTALL REAR SUSPENSION MEMBER BRACE RH
1. Install the suspension member brace with the 4 bolts.
  
  Fig 19: Locating Suspension Member Brace Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 19 N*m (193 kgf*cm, 14 ft.*lbf)
INSTALL REAR SUSPENSION MEMBER BRACE LH
1. Install the suspension member brace with the 4 bolts.
  
  Fig 20: Locating Suspension Member Brace And Bolts (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 19 N*m (193 kgf*cm, 14 ft.*lbf)
INSTALL REAR FLOOR SIDE MEMBER COVER LH
1. Install the member cover with the 3 bolts.
  
  Fig 21: Locating Bolts And Member Cover (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR FLOOR SIDE MEMBER COVER RH
1. Install the member cover with the 3 bolts.
  
  Fig 22: Locating Bolts And Member Cover (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
1. Install the differential supporter with the 2 nuts.
  
  Fig 23: Locating Differential Support Protector Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
1. Install the differential supporter with the 2 nuts.
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY . Refer to INSTALLATION - Step 1
FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY . Refer to INSTALLATION - Step 2
ADJUST NO. 2 AND NO. 3 JOINT ANGLE . Refer to INSTALLATION - Step 3
INSTALL OUTSIDE AIR GUIDE PLATE RH
1. Install the plate with the 4 nuts.
  
  Fig 24: Locating Nuts And Air Guide Plate Outside RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
1. Install the heat insulator with the 5 nuts.
  
  Fig 25: Locating Heat Insulator And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
INSTALL FRONT FLOOR COVER CENTER LH
1. Install the floor cover center with the 3 nuts.
  
  Fig 26: Locating Floor Cover Center With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT FLOOR COVER CENTER RH
1. Install the floor cover center with the 3 nuts.
  
  Fig 27: Locating Floor Cover Center With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST PIPE ASSEMBLY
1. Install the exhaust pipe. Refer to INSTALLATION .
INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Install the sender gauge with the 5 screws.
  
  Fig 28: Locating Fuel Sender Gauge Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf)
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel sender gauge connector.
  
  Fig 29: Locating Rear Floor Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the service hole cover with new butyl tape.
INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
2. Connect the fuel hose, and set the fuel suction with pump and gauge.
  
  Fig 30: Removing Fuel Suction Tube From Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to bend the arm of the fuel sender gauge.
  - When connecting the fuel hose, do not forcibly pull the hose.
3. Install the set plate with the 8 bolts.
  
  Fig 31: Identifying Set Plate With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  HINT:
  
  Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.
4. Install the 2 fuel tank tubes with the 2 tube joint clips.
  
  Fig 32: Identifying Fuel Tank Tubes With Tube Joint Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  Fig 33: Identifying Correct And Incorrect Position Of Collars
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Check that there are no scratches or foreign objects on the connecting parts.
  - Check that the fuel tube joint is 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.
INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
1. Connect the 2 connectors.
  
  Fig 34: Locating Rear Floor No. 2 Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the service hole cover with new butyl tape.
INSTALL ROOM NO. 3 PARTITION PAD
1. Install the partition pad with the clip.
  
  Fig 35: Identifying Partition Pad With Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR SEAT CUSHION ASSEMBLY . Refer to INSTALLATION - Step 4
INSTALL SERVICE PLUG GRIP . Refer to INSTALLATION - Step 33
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHECK FOR FUEL LEAKS . Refer to ON-VEHICLE INSPECTION - Step 1
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.