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Installation [08/2016 - ]: Procedure

  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR 
    1. Install the No. 1 fuel tank heat insulator with the 4 clips.
      GTY576202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.
  2. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. GTY132066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the fuel tank to filler pipe hose to the fuel tank as shown in the illustration.

      HINT: 

      • Align the fuel tank side mark with the hose side mark when installing the hose.
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
        GTY132345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Apply a co-rotation prevention check mark to the fuel suction with pump and gauge tube assembly.

      HINT: 

      Perform this procedure when replacement of the fuel suction with pump and gauge tube assembly is necessary.

      GTY672746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Co-rotation Prevention Check Mark
      Front Side of Vehicle
    2. Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank subassembly.
    3. Set the fuel suction with pump and gauge tube assembly to the fuel tank subassembly.
      GTY615969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Groove
      NOTE:

      Be careful not to bend the arm of the fuel sender gauge assembly.

      HINT: 

      Align the cutout of the fuel suction with pump and gauge tube assembly to the groove of the fuel tank subassembly.

    4. Temporarily place the fuel pump gauge retainer by aligning the rotational start point mark of a new fuel pump gauge retainer with the rotational start point mark of the fuel tank subassembly while pressing the fuel suction with pump and gauge tube assembly into the fuel tank subassembly.
      GTY684143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotational Start Point Mark (Fuel Tank Subassembly Side)
      *b Rotational Start Point Mark (Fuel Pump Gauge Retainer Side)
      Front Side of Vehicle
    5. Set 4 SSTs (claw sets) to the fuel pump gauge retainer and temporarily install.
      • SST: 09808-14031 
        1. 09808-01080
        2. 09808-01090
        3. 09808-01100
      NOTE:
      • Align the cutout of SST (claw set) to the rib of the fuel pump gauge retainer.
      • Do not place SST on the rotational start point mark of the fuel pump gauge retainer, otherwise SST (claw set) cannot be set correctly.
      GTY621473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Rib
      *c Cutout
      *d SST (Claw Set) Incorrect Installation Point (Rotational Start Point Mark of Fuel Pump Gauge Retainer)
    6. While firmly pressing the claw of SST (claw set) into rib of the fuel pump gauge retainer, tighten the bolt.
      GTY665529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Hook
      Press
      SST (Bolt)
    7. Temporarily install SST (plate) to SST (claw set) with 4 SSTs (bolts).
      GTY682224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Plate)
      *b SST (Claw Set)
      SST (Bolt)
    8. Adjust the position of SST (plate) so that the setting hole of SST (handle) aligns with the center of the fuel pump gauge retainer.
      GTY682305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Center of Fuel Pump Gauge Retainer
      *b SST (Plate)
      Front Side of Vehicle
    9. While firmly pressing the SST (claw set) into rib of the fuel pump gauge retainer, tighten SST (bolt).
      GTY652926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Pump Gauge Retainer
      *a SST (Plate)
      *b SST (Claw Set)
      *c SST (Bolt)
      *d Rib
      Press
    10. While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank subassembly, have another person firmly press the fuel pump gauge retainer into the threads of the fuel tank subassembly and tighten approximately one and a half turns.
      NOTE:
      • Do not use any tools other than SST, such as a screwdriver, etc.
      • Do not use excessive force when pressing down on SST, as the fuel suction with pump and gauge tube assembly will place excessive force on the pump gauge retainer and be difficult to remove, and parts may be damaged.
      • Do not use an impact wrench or turn the SST handle with excessive force, as parts may be damaged.
      • Do not rotate the fuel pump gauge retainer when the co-rotation prevention check mark is out of place.
      GTY622252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Co-rotation Prevention Check Mark
      *b Tightening Start Position
      *c One and Half Rotation Position
      Front Side of Vehicle
    11. While one person presses the fuel suction with pump and gauge tube assembly into the fuel tank subassembly, have another person slowly tighten approximately 180°.
      GTY622702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Plate)
      *b Person in Charge of Tightening
      *c Person in Charge of Supporting
      *d Approximately 180°
      Front Side of Vehicle
    12. Check the tightening condition of the fuel pump gauge retainer.
      1. Using a vernier caliper, measure the upper surface dimensions of the fuel tank subassembly at the 3 positions as shown in the illustration.

        Standard

        Measurement difference is within 3 mm.

        NOTE:

        If the measurement difference is approximately 6 mm, the threads misaligned by 1 threads (6 mm) and the fuel pump gauge retainer must be installed again.

        GTY652705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Subassembly
        *a Vernier Caliper
        *b Measurement Position
        *c Measurement Height
        Front Side of Vehicle
    13. Install SST (handle) to SST (plate).
      • SST: 09808-14031 
        1. 09808-01010
        2. 09808-01020
      GTY624342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a SST (Handle)
      *b SST (Plate)
      *c Tightening Complete Position
      *d Rotational Start Point Mark of Fuel Pump Gauge Retainer
      *e Rotational Start Point Mark of Fuel Tank Subassembly
      *f Person in Charge of Tightening
      *g Person in Charge of Supporting
      Tighten
    14. While one person presses the fuel suction with pump and gauge tube assembly onto the fuel tank subassembly, have another person use SST (handle) and slowly tighten the fuel pump gauge retainer until it reaches the tightening complete position.
  4. INSTALL FUEL TANK MAIN TUBE SUBASSEMBLY AND FUEL TANK RETURN TUBE SUBASSEMBLY 
    1. Install the 2 fuel tank tubes and No. 1 fuel tube joint with the 3 tube joint clips.
      GTY137614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      GTY579093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there are no scratches or foreign objects on the connecting parts.
      • Check that the fuel tube joints are 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.
    2. Install the fuel tank main tube and fuel tank return tube to the fuel tank.
      GTY610965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK SUBASSEMBLY 
    1. Set the fuel tank on a transmission jack and raise the fuel tank.
    2. Raise the transmission jack.
    3. Install the 2 fuel tank bands with the 2 pins and 2 clips.
      GTY611333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 2 fuel tank bands with the 2 bolts.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  6. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. GTY559739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the fuel tank to filler pipe hose to the fuel tank filler pipe as shown in the illustration.

      HINT: 

      • Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.
      • Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
        GTY132345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT FUEL TANK BREATHER TUBE SUBASSEMBLY 
    1. Connect the fuel tank breather tube to the fuel tank filler pipe.
      GTY540987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
  8. CONNECT NO. 2 FUEL TANK BREATHER TUBE SUBASSEMBLY 
    1. Connect the No. 2 fuel tank breather tube.
      GTY238065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the hose, make sure that it is not damaged. Make sure that there is no foreign matter present on the connecting surfaces.
      • After connecting, check if the hose and the connector are securely connected by pulling on them.
    2. Attach the 2 fuel tube clamps.
  9. CONNECT FUEL TANK RETURN TUBE 
    1. Connect the fuel tank return tube.
      GTY579465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
  10. CONNECT FUEL TANK MAIN TUBE SUBASSEMBLY 
    1. Connect the fuel tank main tube.
      GTY594916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

      NOTE:
      • Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
    2. Attach the fuel tube clamp.
  11. INSTALL NO. 1 FUEL TANK PROTECTOR SUBASSEMBLY 
    1. GTY577698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the tank protector with the 5 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  12. INSTALL FUEL TANK CAP ASSEMBLY 
  13. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    1. GTY574499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the fuel pump and fuel sender gauge connector.

    2. GTY574496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the service hole cover with new butyl tape.

    3. GTY605547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the air duct with the 2 screws.

  14. INSTALL FRONT FLOOR CARPET ASSEMBLY 

    Refer to PROCEDURE - Step 3 [08/2015 - 08/2019] Refer to PROCEDURE - Step 3 [08/2019 - ]

  15. INSTALL REAR AIR DUCT GUIDE 

    Refer to PROCEDURE - Step 10

  16. INSTALL AIR DUCT PLUG 

    Refer to PROCEDURE - Step 11

  17. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH 

    Refer to PROCEDURE - Step 58 [08/2015 - 08/2017] Refer to PROCEDURE - Step 61 [08/2017 - 08/2019] Refer to PROCEDURE - Step 67 [08/2019 - ]

  18. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH 

    Refer to PROCEDURE - Step 57 [08/2015 - 08/2017] Refer to PROCEDURE - Step 60 [08/2017 - 08/2019] Refer to PROCEDURE - Step 66 [08/2019 - ]

  19. INSTALL NO. 1 LUGGAGE COMPARTMENT TRIM HOOK 

    Refer to PROCEDURE - Step 60 [08/2015 - 08/2017] Refer to PROCEDURE - Step 63 [08/2017 - 08/2019] Refer to PROCEDURE - Step 70 [08/2019 - ]

  20. INSTALL REAR FLOOR MAT REAR SUPPORT PLATE 

    Refer to PROCEDURE - Step 71 [08/2015 - 08/2017] Refer to PROCEDURE - Step 74 [08/2017 - 08/2019] Refer to PROCEDURE - Step 81 [08/2019 - ]

  21. INSTALL REAR NO. 2 SEAT ASSEMBLY 
    1. Install the rear No. 2 seat assembly (Refer to INSTALLATION [08/2015 - ] ).
  22. INSTALL REAR DOOR SCUFF PLATE RH 

    Refer to PROCEDURE - Step 73 [08/2015 - 08/2017] Refer to PROCEDURE - Step 76 [08/2017 - 08/2019] Refer to PROCEDURE - Step 83 [08/2019 - ]

  23. INSTALL REAR DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 72 [08/2015 - 08/2017] Refer to PROCEDURE - Step 75 [08/2017 - 08/2019] Refer to PROCEDURE - Step 82 [08/2019 - ]

  24. INSTALL REAR STEP COVER 

    Refer to PROCEDURE - Step 74 [08/2015 - 08/2017] Refer to PROCEDURE - Step 77 [08/2017 - 08/2019] Refer to PROCEDURE - Step 84 [08/2019 - ]

  25. INSTALL REAR NO. 2 SEAT PROTECTOR 

    Refer to PROCEDURE - Step 15 [08/2015 - 08/2019] Refer to PROCEDURE - Step 18 [08/2019 - ]

  26. INSTALL REAR NO. 1 SEAT PROTECTOR 

    Refer to PROCEDURE - Step 16 [08/2015 - 08/2019] Refer to PROCEDURE - Step 19 [08/2019 - ]

  27. INSTALL REAR NO. 1 SEAT ASSEMBLY RH 
    1. Install the rear No. 1 seat assembly (Refer to INSTALLATION [08/2015 - 08/2019] Refer to INSTALLATION [08/2019 - ] ).
  28. INSTALL REAR NO. 1 SEAT ASSEMBLY LH 
    1. Install the rear No. 1 seat assembly (Refer to INSTALLATION [08/2015 - 08/2019] Refer to INSTALLATION [08/2019 - ] ).
  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  30. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (Refer to DIAGNOSIS SYSTEM [08/2015 - ] ).
  31. ADD FUEL 
  32. INSPECT FOR FUEL LEAK 

    See step  12

  33. INSPECT REAR NO. 1 SEAT ASSEMBLY RH 

    Refer to PROCEDURE - Step 25 [08/2015 - 08/2019] Refer to PROCEDURE - Step 28 [08/2019 - ]

  34. INSPECT REAR NO. 1 SEAT ASSEMBLY LH 

    Refer to PROCEDURE - Step 25 [08/2015 - 08/2019] Refer to PROCEDURE - Step 28 [08/2019 - ]

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