Installation [09/2020 - ]: Procedure

1. Install the No. 2 fuel tank protector and No. 3 fuel tank protector to the fuel tank assembly.
2. Install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly.

   HINT: 

   Install the No. 1 fuel tank protector sub-assembly after installing the No. 2 fuel tank protector and No. 3 fuel tank protector.

1. Install the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set to the fuel tank assembly.
2. Install 5 new No. 6 fuel tank cushions to the fuel tank assembly.

1. Engage the 2 clamps to install the No. 3 fuel tube clamp and No. 5 fuel tube clamp to the fuel tank assembly.
2. Engage the 3 clamps to install the fuel tank main tube sub-assembly to the fuel tank assembly.

1. Set the fuel tank assembly on an engine lifter with attachments.

   HINT: 

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

2. Using the engine lifter, slowly raise the fuel tank assembly, and then install the fuel tank assembly with the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.

   Nut 

   Torque: 19.6 N*m (200 kgf*cm, 14 ft.*lbf) 

   Bolt 

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

   NOTE:

   • Be careful not to drop the fuel tank assembly.
   • When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

Refer to PROCEDURE - Step 17 [09/2020 - 10/2022] , or refer to PROCEDURE - Step 17 [10/2022 - ]

Refer to PROCEDURE - Step 18 [09/2020 - 10/2022] , or refer to PROCEDURE - Step 18 [10/2022 - ]

1. Install the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly with the 2 bolts and 2 nuts.

   Bolt 

   Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

   Nut 

   Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

2. Engage the 4 clamps.

1. Push the fuel tank breather tube onto the fuel tank filler pipe sub-assembly and push in the retainer to engage the 2 claws.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Breather Tube Clamp
   *a	Retainer
   *b	Claw
   	Push
   	Push in

   NOTE:

   • Check that there are no scratches or foreign matter around the connecting parts of the fuel tank breather tube connector and fuel tank to filler pipe hose before performing this work.
   • After connecting the fuel tank breather tube, check that the fuel tank breather tube is securely connected by pulling on the fuel tank breather tube.
2. Engage the clamp to connect the fuel tank breather tube to the breather tube clamp.

1. Push the fuel cut off valve tube onto the fuel tank vent hose and push in the retainer to engage the lock claws.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Evaporation Vent Tube Clamp
   *a	Retainer
   	Push
   	Push in

   NOTE:

   • Check that there are no scratches or foreign matter around the connecting parts of the fuel cut off valve tube connector and fuel tank vent hose before performing this work.
   • After connecting the fuel cut off valve tube, check that the fuel cut off valve tube is securely connected by pulling on the fuel cut off valve tube.
2. Engage the clamp to connect the fuel cut off valve tube to the No. 1 evaporation vent tube clamp.

1. Connect the fuel tank to filler pipe hose.
   NOTE:

   Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

   1. Align the fuel tube connector with the fuel pipe (fuel tank assembly), push the fuel tube connector onto the fuel pipe (fuel tank assembly), then push in the retainer to secure the connection.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Retainer
      	Push
      	Push in

      NOTE:

      Confirm that the retainer makes a "click" sound when pushed.

      HINT: 

      If it is difficult to push the fuel tube connector onto the fuel pipe (fuel tank assembly), apply a small amount of clean gasoline to the tip of the fuel pipe (fuel tank assembly).

   2. After connecting the fuel lines, check that the fuel pipe (fuel tank assembly) and fuel tube connector are securely connected by pulling on them.

1. Install the No. 2 fuel tank filler pipe support to the No. 3 center floor cross member sub-assembly with the bolt.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

1. Connect the fuel tank main tube sub-assembly to the fuel pipe.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Retainer
   *b	Fuel Tube Connector
   *c	Nylon Tube
   *d	O-ring
   *e	Fuel Pipe
   *f	Claw
   	Push
   	Push in

   1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.
   2. Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
2. for Half Cover Type:
   1. Install the 2 No. 1 fuel tube protectors to the fuel tank main tube sub-assembly.

Refer to PROCEDURE - Step 81 [09/2020 - 10/2022] , or refer to PROCEDURE - Step 79 [10/2022 - ]

Refer to PROCEDURE - Step 82 [09/2020 - 10/2022] , or refer to PROCEDURE - Step 80 [10/2022 - ]

Refer to INSTALLATION [09/2014 - ]

Refer to INSTALLATION [10/2015 - ] 

Refer to INSTALLATION [10/2015 - ]