Fuel Tank: Installation

INSTALL FUEL TANK ASSEMBLY
1. Set the fuel tank on a transmission jack.
2. Lift up the transmission jack.
3. Fold back approximately half of any cushion rubber necessary for the attachment of the wire harness to the fuel tank.
4. Connect the fuel pump connector and sender gauge connector.
  NOTE: Be careful not to cut the wiring.
5. Attach the wire harness to the 4 clamps.
  
  Fig 1: Attaching Wire Harness To Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the 3 fuel tank bands with the 6 bolts.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
INSTALL FUEL TANK FILLER PIPE SUB-ASSEMBLY
1. Install the filler pipe with the 2 bolts.
  Torque: 24 N*m (240 kgf*cm, 17 ft.*lbf)
2. Install the filler pipe protector with the 3 bolts.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 2: Locating Filler Pipe Protector With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK TO FILLER PIPE HOSE
1. Connect the filler pipe hose to the fuel tank as shown in the illustration.
  HINT:
  - Position the fuel tank to filler pipe hose so that the protrusion faces towards the bottom of the fuel tank when connecting the hose.
  - Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
    
    Fig 3: Connecting Filler Pipe Hose To Fuel Tank
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL HOSE PROTECTOR
1. Attach the claw to install the fuel hose protector to the filler pipe hose.
  
  Fig 4: Identifying Fuel Hose Protector Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY
1. Connect the fuel tank breather tube to the fuel filler pipe.
  NOTE:
  - Before installing the tube connector to the pipe, check the connector for damage and foreign matter.
  - Check that the connector and pipe are securely connected by trying to pull them apart.
    
    Fig 5: Connecting Fuel Tank Breather Hose To Fuel Tank
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT AIR INLET LINE TUBE
1. Attach the clamp to connect the air inlet line tube to the fuel tank band.
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
NOTE: Before installing the tube connector to the pipe, check the connector for damage and foreign matter.

Fig 6: Identifying Fuel Tank Main Tube Claw
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Connect the main tube connector to the pipe. Push the 2 parts together firmly until a "click" sound is heard.
  NOTE: Check that the connector and pipe are securely connected by trying to pull them apart.
2. Connect the vent line tube to the fuel tank.
  
  Fig 7: Connecting EVAP Hose To Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY
1. Connect the parking brake cable with the 2 bolts.
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
  
  Fig 8: Locating Parking Brake Cable With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL GAUGE WIRE
1. Pass the sensor connectors through the floor panel and install the grommet.
2. Connect the connector and clamp.
  
  Fig 9: Locating Grommet And Sensor Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the 2 connectors and attach the clamp.
INSTALL FUEL TANK CAP ASSEMBLY
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSTALL REAR CONSOLE BOX SUB-ASSEMBLY
1. Install the rear console box sub-assembly (See INSTALLATION ).
INSPECT FOR FUEL LEAK (See INSTALLATION )

Fig 10: Locating Fuel Gauge Wire Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002