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Fuel Tank: Installation

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  1. INSTALL FUEL TANK CUSHION SET 
    1. Install the fuel tank cushion sets and No. 5 fuel tank cushions.
    Fig 1: Identifying Fuel Tank Cushion Sets And No. 5 Fuel Tank Cushions
    G05414881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FUEL TANK SIDE PLATE 
    1. Install the fuel tank side plate and the fuel tank bracket with the bolt and nut.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      Fig 2: Identifying Fuel Tank Side Plate And Fuel Tank Bracket
      G05414880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TANK SUCTION TUBE SUPPORT 
    1. Install a new tank suction tube support as shown in the illustration.
    Fig 3: Identifying Tank Suction Tube Support
    G05414884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSEMBLY 
    1. Install a new tank suction tube support and new gasket as shown in the illustration.
      Fig 4: Identifying Tank Suction Tube Support And Gasket
      G05414885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the fuel tank over fill check valve assembly to the fuel tank.
    3. Align the keyway of the fuel suction tube support with the key of the fuel tank over fill check valve assembly.
      Fig 5: Aligning Keyway Of Fuel Suction Tube Support With Key Of Fuel Tank Over Fill Check Valve Assembly
      G05414886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Align the triangle mark on a new fuel pump gauge retainer with the "S" mark, and attach the fuel pump gauge retainer.
      Fig 6: Identifying Triangle And S Mark On Fuel Pump Gauge Retainer
      G05414887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a 6 mm socket hexagon wrench, install SST to the fuel pump gauge retainer.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      HINT:

      • Engage the SST claws securely with the fuel pump gauge retainer ribs to secure SST.
      • Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST).
      Fig 7: Installing SST To Fuel Pump Gauge Retainer
      G05414875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Rotate the fuel pump gauge retainer by hand, then tighten it one complete turn and another half turn using SST. The triangle mark on the fuel pump gauge retainer must be positioned between the "MIN" and "MAX" marks on the fuel tank.

      SST 09808-14020 (09808-01410, 09808-01420, 09808-01430) 

      NOTE:
      • Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
      • Fully tighten the retainer by turning it clockwise while holding SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.

      HINT:

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

      Fig 8: Rotating Fuel Pump Gauge Retainer
      G05414889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FUEL TANK VENT HOSE 
    1. Connect the No. 1 evaporation vent tube.
      1. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a click sound. If the connection is too tight, apply a small amount of fresh engine oil to the tip of the pipe.
        NOTE:
        • Check for damage or foreign objects on the parts that are to be connected.
        • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
        Fig 9: Pushing Pipe Into Connector
        G05414890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the fuel tank vent hose.
      1. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a click sound. If the connection is too tight, apply a small amount of fresh engine oil to the tip of the pipe.
        NOTE:
        • Check for damage or foreign objects on the parts that are to be connected.
        • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      2. Install the fuel tank vent hose, and engage the claw.
      Fig 10: Pushing Pipe Into Connector
      G05414891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FUEL TANK TO FILLER PIPE HOSE 
    1. Install the fuel tank to filler pipe hose with the hose clamp.
    Fig 11: Locating Hose Clamp Bolt
    G05414872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY 
    1. Install the fuel pump tube, and engage the 2 claws.
    Fig 12: Identifying Fuel Pump Tube Claws
    G05414871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 1 FUEL TANK CUSHION 
    1. Apply new butyl tape to the positions of the No. 1 fuel tank cushion as shown in the illustration.

      Length 

      DIMENSION REFERENCE

      Dimension Length
      A 55 mm (2.17 in.)
      B 20 mm (0.79 in.)
      C 60 mm (2.36 in.)
      D 20 mm (0.79 in.)
      E 80 mm (3.15 in.)
      F 20 mm (0.79 in.)
      G 53.4 mm (2.10 in.)
      H 49.2 mm (1.94 in.)
      I 18.9 mm (0.74 in.)
      J 43.3 mm (1.70 in.)
    2. Install the No. 1 fuel tank cushion.
    Fig 13: Identifying No. 1 Fuel Tank Cushion Dimension
    G05414894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR FUEL TANK SIDE PLATE 
    1. Install the rear fuel tank side plate.
  10. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank onto a transmission jack.
    2. Operating the transmission jack, install the fuel tank.
      Fig 14: Identifying Rear Fuel Tank Side Plate
      G05414869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 2 nuts.
      Fig 15: Locating Fuel Tank Assembly Bolts, Nuts And Fuel Tank Bands
      G05414868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

    4. Install the 2 fuel tank bands with the 4 bolts.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

    5. Align the matchmarks and install the fuel tank to filler pipe hose to the fuel tank.
    6. Install the hose clamp within the range shown in the illustration.

      HINT:

      • A = 45°
      • B =120°
      Fig 16: Installing Hose Clamp
      G05414897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the fuel tank vent hose.
      1. Align the quick connector with the pipe, then push in the quick connector until the retainer makes a click sound to connect the charcoal canister fuel hose to the charcoal canister assembly.
        NOTE:
        • Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this work.
        • After connecting the charcoal canister fuel hose, check if the quick connector and the pipe are securely connected by pulling on them.
        Fig 17: Connecting Fuel Tank Vent Hose
        G05414898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the No. 3 fuel tank breather tube.
      1. Push the quick connector to the pipe until it makes a click sound.
        NOTE:
        • Check if there is any damage or foreign objects on the connected part.
        • After connecting, check if the quick connector and the pipe are securely connected by pulling on them.
        Fig 18: Connecting No. 3 Fuel Tank Breather Tube
        G05414899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the fuel pump tube.
      1. Push the quick connector and push in the retainer to lock the claws.
        NOTE:
        • Check if there is any damage or foreign objects on the connected part.
        • After connecting, check if the quick connector and the pipe are securely connected by pulling on them.
        Fig 19: Connecting Fuel Pump Tube
        G05414900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the No. 1 fuel tank protector sub-assembly with the 7 nuts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

    2. Install 3 new clips (A).
  12. INSTALL NO. 3 FRONT FLOOR HEAT INSULATOR  (See INSTALLATION )
    Fig 20: Locating No. 1 Fuel Tank Protector Sub-Assembly Clips And Nuts
    G05414863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 4 EXHAUST PIPE SUPPORT BRACKET 
    1. Install the No. 4 exhaust pipe support bracket with the 2 bolts.

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

  14. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  15. INSTALL TAIL EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
    Fig 21: Locating No. 4 Exhaust Pipe Support Bracket Bolts
    G05414862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL CENTER FRONT FLOOR COVER  (See INSTALLATION )
  17. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE 
    1. Install the fuel suction tube assembly with pump and gauge (See INSTALLATION ).
  18. INSPECT EXHAUST GAS LEAK 
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