Fuel Tank: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL FUEL TANK ASSEMBLY
1. Set the fuel tank on a mission jack.
2. Raise the mission jack.
3. Fold back the 2 cushion rubbers.
4. Connect the fuel pump connector and sender gauge connector to the fuel tank.
  NOTE: Be careful not to cut the wirings.
  
  Fig 1: Identifying Fuel Tank Cushion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Attach the wire harness to the 4 clamps.
6. Install the 3 fuel tank bands with the 6 bolts.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 2: Identifying Fuel Tank Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK FILLER PIPE
1. Install the filler pipe with the 2 bolts.
  Torque: 23.5 N*m (240 kgf*cm, 17 ft.*lbf)
2. Install the filler pipe protector with the 3 bolts.
  
  Fig 3: Identifying Fuel Tank To Filler Pipe Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK TO FILLER PIPE HOSE
1. Connect the filler pipe hose to the fuel tank.
CONNECT FUEL TANK BREATHER HOSE
1. Connect the fuel tank breather hose to the fuel tank.
  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 4: Identifying Fuel Tank Breather Hose To Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
NOTE: Before installing the tube connector to the pipe, check the connector for damage and foreign matter.
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 EVAP hose to the fuel tank.
  
  Fig 5: Connecting EVAP Hose To Fuel Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FLOOR UNDER COVER
1. Install the floor cover with the clip and 2 nuts.
  
  Fig 6: Identifying Floor Under Cover With Clips, Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT FLOOR COVER
1. Install the floor under cover with the 3 clips, bolt and nut.
INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY
1. Install the parking brake cable with the 2 bolts.
  
  Fig 7: Identifying Parking Brake Cable With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL TANK CAP
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHECK FOR FUEL LEAKS