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Installation [11/2021 - ]: Procedure

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  1. INSTALL NO. 4 FUEL TANK CUSHION 
  2. INSTALL NO. 3 FUEL TANK CUSHION 
  3. INSTALL NO. 2 FUEL TANK CUSHION 
  4. INSTALL NO. 1 FUEL TANK CUSHION 
  5. INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY 
    1. GTY1076424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Fuel Return Vent Tube Sub-assembly - -
      Front of the Vehicle - -
      1. Install the fuel return vent tube sub-assembly to the fuel tank sub-assembly.
        NOTE:

        Make sure to correctly assemble the fuel return vent tube sub-assembly as shown in the illustration. If assembled incorrectly, the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) may catch on the fuel return vent tube sub-assembly resulting in incorrect operation of the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) and an incorrect value being displayed on the fuel gauge.

  6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
  7. INSTALL FUEL TANK SUB-ASSEMBLY 
    WARNING:

    The fuel tank sub-assembly is very heavy. Be sure to follow the procedure described in the repair information, or the fuel tank sub-assembly may fall off the engine lifter.

    GTY563885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Fig 1: Fuel Tank Sub-Assembly Bolts Tightening Sequence
      GTY1075102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a LH Side *b RH Side
      *c Torque Wrench Fulcrum Length - -
      1. Set the fuel tank sub-assembly on an engine lifter.
        NOTE:

        Using height adjustment attachments and plate lift attachments, keep the fuel tank sub-assembly horizontal.

      2. Using the engine lifter, slowly raise the fuel tank sub-assembly, and then temporarily install the fuel tank sub-assembly and 2 fuel tank band sub-assemblies with the 4 bolts.
        NOTE:
        • Be careful not to drop the fuel tank sub-assembly.
        • When installing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the surrounding parts.
      3. Tighten the 4 bolts in the order shown in the illustration.

        Specified tightening torque: 

        Torque: 45 N.m (459 kgf/cm, 33 ft.lbf) 

      4. Using SST, install the rear side of the fuel tank band sub-assembly.
        • SST: 09961-00950 

        Specified tightening torque: 

        Torque: 45 N.m (459 kgf/cm, 33 ft.lbf) 

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [11/2021 - ]

        • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24.5 N.m (250 kgf/cm, 18 ft.lbf)
  8. CONNECT FUEL TANK FILLER PIPE ASSEMBLY 
    1. GTY1075646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tank filler pipe assembly to the fuel tank sub-assembly.

        Refer to PRECAUTION [11/2021 - ]

  9. CONNECT FUEL TANK BREATHER TUBE 
    1. GTY1074828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tank breather tube to the fuel tank breather tube sub-assembly.

        Refer to PRECAUTION [11/2021 - ]

  10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. GTY1075483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tank main tube sub-assembly to the fuel pipe.

        Refer to PRECAUTION [11/2021 - ]

  11. CONNECT FUEL TANK EVAP/VENT TUBE SUB-ASSEMBLY 
    1. GTY1074942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tank evap/vent tube sub-assembly to the fuel tank vent hose sub-assembly.

        Refer to PRECAUTION [11/2021 - ]

      2. Engage the clamp.
  12. INSTALL NO. 1 FUEL TANK PROTECTOR 
  13. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 

    Torque: 10.5 N.m (107 kgf/cm, 8 ft.lbf) 

  14. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    Refer to INSTALLATION [11/2021 - ]

  15. INSTALL TAIL EXHAUST PIPE ASSEMBLY 

    Refer to INSTALLATION [11/2021 - ]

  16. ADD FUEL 
  17. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY 

    Refer to INSTALLATION [11/2021 - ] 

  18. INSTALL FUEL TANK VENT TUBE ASSEMBLY 

    Refer to INSTALLATION [11/2021 - ] 

  19. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  20. INSTALL NO. 1 FLOOR UNDER COVER 

    Bolt 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  21. INSTALL FRONT FLOOR COVER RH 

    Bolt 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  22. INSTALL NO. 2 FLOOR UNDER COVER 

    Bolt 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  23. INSTALL FRONT FLOOR COVER LH 

    Bolt 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  24. INSTALL FRONT SUSPENSION MEMBER DYNAMIC DAMPER 

    Refer to PROCEDURE - Step 79 [11/2021 - 03/2023] , or refer to PROCEDURE - Step 80 [03/2023 - ]

  25. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 6

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