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Fuel Tank: Installation

  1. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank onto a transmission jack.
    2. Operate the transmission jack, then install the fuel tank into the vehicle.
    3. Install the 2 fuel tank bands with the 4 bolts.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

      Fig 1: Locating Fuel Tank Bands With Bolts
      G04865760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the fuel tank to filler pipe hose to the fuel tank, then tighten the hose clamp.
      NOTE: Make sure that the mark and hose clamp are at the correct angle when installing.
      Fig 2: Aligning Hose Clamp With Mark
      G04865778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the fuel hose protector.
      Fig 3: Locating Fuel Hose Protector
      G04865779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the fuel tank breather tube to the fuel tank.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector until the retainer makes a "click" sound to connect the fuel tube breather tube to the pipe.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
        • After connecting the fuel tube connector, check that the fuel tube connector and pipe are securely connected by pulling them.
          Fig 4: Locating Fuel Tube Connector
          G04865780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the fuel tank main tube.
      1. Align the fuel tube connector with the pipe, then push the fuel tube connector until the it comes into contact with the seat to connect the fuel tank main tube to the pipe. Then push the retainer up until the claws lock.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
        • After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling the fuel tube connector and pipe.
          Fig 5: Pushing Fuel Tube Connector
          G04865781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL REAR SUSPENSION BRACE LOWER RH 
    1. Install the rear suspension brace lower with the 2 bolts.

      Torque: 63.5 N*m (645 kgf*cm, 47 ft.*lbf) 

      Fig 6: Identifying Rear Suspension Brace Lower RH With Bolts
      G04865753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL REAR SUSPENSION BRACE LOWER LH 
    1. Install the rear suspension brace lower with the 3 bolts.

      Torque: 63.5 N*m (645 kgf*cm, 47 ft.*lbf) 

  4. INSTALL CANISTER ASSEMBLY (See  INSTALLATION  ) 
    Fig 7: Identifying Rear Suspension Brace Lower LH With Bolts
    G04865752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 FUEL TANK PROTECTOR 
    1. Install the No. 1 fuel tank protector with the 5 bolts.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      2. Fig 8: Identifying Fuel Tank Protector And Bolts
      G04865751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See  INSTALLATION  ) 
  7. ADD FUEL 
  8. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (See  INSTALLATION  )
  9. INSTALL REAR FLOOR SERVICE HOLE COVER (See  FUEL TANK  )
  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  11. 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.
  12. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  )
  13. INSTALL REAR SEAT CUSHION ASSEMBLY (See  INSTALLATION  ) 
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