Fuel Tank: Installation

1. Install 4 new fuel tank cushions No. 1 onto the fuel tank.
   Fig 1: Installing Fuel Tank Cushions No. 1 Onto Fuel Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the fuel onto the fuel tube clamp.
   Fig 2: Installing Fuel Onto Fuel Tube Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the fuel tank main tube onto the fuel tank.
   Fig 3: Installing Fuel Tank Main Tube Onto Fuel Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the fuel tank on a transmission jack [A].
2. Operate the transmission jack, then install the fuel tank into the vehicle [B].
3. Install the 2 fuel tank bands No. 1 with the 4 bolts [C].

   Torque: 39 Nm (400 kgf cm, 29 ft. lbf) 

   Fig 4: Installing Fuel Tank Bands No. 1 With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the fuel tank to filler pipe hose to the fuel tank
   NOTE: Make sure that the hose clamp is at the correct direction when installing.
   Fig 5: Connecting Fuel Tank To Filler Pipe Hose To Fuel Tank

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Align the claw position, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
   Fig 6: Aligning Claw Position

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the fuel tank vent hose.
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
   2. Slide the retainer of the fuel tube connector to the claws lock as shown in the illustration.
      NOTE:

      • Check that the 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 vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tube connector.
        Fig 7: Connecting Fuel Tank Vent Hose

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the fuel tank breather tube.
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank 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 tank breather tube, check that the fuel pump tube is securely connected by pulling the fuel tube connector and pipe.
        Fig 8: Connecting Fuel Tank Breather Tube

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the checker onto the pipe.
8. Connect the fuel tank main tube.
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector into until 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 9: Connecting Fuel Tank Main Tube

        Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the turn prevention positions, then connect the parking brake cable No. 3 with the 2 bolts.

   Torque: 5.4 Nm (55 kgf cm, 48 in. lbf) 

   Fig 10: Connecting No. 3 Parking Brake Cable Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Align the turn prevention positions, then connect the parking brake cable No. 2 with the 2 bolts.

   Torque: 5.4 Nm (55 kgf cm, 48 in. lbf) 

   Fig 11: Connecting No. 2 Parking Brake Cable Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the free length.
   1. Using vernier calipers, measure the free length of the compression spring.

      Minimum: 

      Exhaust manifold side: 41.5 mm (1.6339 in.) 

      Exhaust pipe tail side: 38.5 mm (1.5158 in.) 

      If the free length is less than minimum, replace the compression spring.

      Fig 12: Measuring Free Length Of Compression Spring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a wooden block and plastic-faced hammer, tap a new gasket into the exhaust manifold.
   NOTE:

   • Make sure that the gasket is in the correct direction when installing.
   • Do not reuse a removed gasket.
   • Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust manifold.
     Fig 13: Taping Gasket Into Exhaust Manifold Using Wooden Block And Plastic-Faced Hammer

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a wooden block and plastic-faced hammer, tap a new gasket into the exhaust tail.
   NOTE:

   • Make sure that the gasket is in the correct direction when installing.
   • Do not reuse a removed gasket.
   • Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust tail.
4. Install the exhaust pipe front onto the 2 exhaust pipe supports No. 4 [D].
5. Tighten the 4 compression springs and 4 bolts [E].

   Torque: 43 Nm (440 kgf cm, 32 ft. lbf) 

   Fig 14: Taping Gasket Into Exhaust Tail Using Wooden Block And Plastic-Faced Hammer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Fig 15: Installing Exhaust Pipe Front Onto Exhaust Pipe Supports No. 4

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the floor panel brace front with 2 nuts [F].

   Torque: 30 Nm (302 kgf cm, 22 ft. lbf) 

   Fig 16: Installing Floor Panel Brace Front With Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Pull the connector back inside the vehicle, then install the grommet [G].
8. Connect the heated oxygen sensor connector [H].
   Fig 17: Connecting Heated Oxygen Sensor Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Pull the connector back inside the vehicle, then install the grommet [I].
10. Connect the heated oxygen sensor connector [J].
    Fig 18: Connecting Heated Oxygen Sensor Connector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Install the floor carpet front with the clip [K].

Torque: 5.4 Nm (55 kgf cm, 48 in. lbf) 

Fig 19: Installing Floor Carpet Front With Clip

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

PRECAUTION