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Installation [09/2015 - ]: Procedure

  1. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY 
    1. Install the fuel tank protector to the fuel tank.
  2. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Install the fuel tube 6 clamps.
      GTY685817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel tank main tube to the fuel tank with the 6 clamps.
  3. INSTALL FUEL TANK RETURN VENT TUBE 
    1. Install the fuel tank return vent tube to the fuel tank.
      GTY655598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Install the vent hose to the fuel tank.
      GTY139879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for damage or foreign matter around the connecting parts of the vent hose and fuel tank.
      • After connecting, check that the vent hose and the valve are securely connected by pulling on them.
  5. INSTALL FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Install the fuel suction tube.
      GTY651906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

      HINT: 

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

  6. INSTALL FUEL TANK WIRE 
    1. Attach the 6 clamps of the fuel tank wire to install the wire to the fuel tank.
      GTY634127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FUEL TANK PRESSURE SENSOR 

    (Refer to INSTALLATION [09/2015 - ] )

  8. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank on a engine lifter and raise the fuel tank.
      NOTE:

      Do not allow the fuel tank to contact the vehicle, especially the differential.

    2. Connect the fuel tank to the fuel filler pipe and slide the filler pipe clamp.
      GTY142728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      GTY636277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Insert the filler pipe into the fuel tank with their axes aligned. If not aligned, the insertion load increases.
      • Do not twist or forcefully insert the filler pipe.
      • After securely inserting the filler pipe into the fuel tank, attach the clamp. At this time, securely insert the clamp into the slit.
    3. Temporarily install the 2 fuel tank bands with the 4 bolts.
      GTY685990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the bolts in the front.

      Torque: 39 N*m (408 kgf*cm, 30 ft.*lbf) 

    5. Using SST, a torque wrench and union nut wrench, tighten the bolts in the rear.
      • SST: 09961-00950 
      GTY639774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      without SST 

      Torque: 39 N*m (408 kgf*cm, 30 ft.*lbf) 

      with SST 

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

      HINT: 

      • Use a torque wrench with a fulcrum length of 180 mm (7.09 in.). If using a torque wrench with a length that is not 180 mm (7.09 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification (Refer to PRECAUTION [09/2015 - ] ).
      • Make sure union nut wrench, SST and torque wrench are connected in a straight line.
  9. CONNECT FUEL TANK WIRE 
    1. Connect the fuel vapor containment valve connector and attach the 2 clamps.
      GTY634121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT FUEL SUCTION TUBE SUB-ASSEMBLY 
    1. Connect the fuel suction tube.
      GTY664831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

      HINT: 

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

  11. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY 
    1. Connect the fuel tank vent hose.
      GTY649859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the hose connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

      HINT: 

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

  12. CONNECT FUEL TANK RETURN VENT TUBE 
    1. Connect the fuel tank return vent tube.
      GTY672816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

      HINT: 

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

  13. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    1. Connect the fuel tank main tube LH.
      GTY668387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

      HINT: 

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

    2. Connect the fuel tank main tube RH.
      GTY662488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      • After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

      HINT: 

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

  14. INSTALL FUEL TANK PROTECTOR BRACKET SIDE 
    1. Install the protector with the 2 bolts.
      GTY674401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  15. INSTALL FUEL TANK FILLER PIPE PROTECTOR 
    1. Install the tank protector with the 2 clips and 2 nuts.
      GTY674400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  16. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    (Refer to INSTALLATION [09/2015 - ] )

  17. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY 
    1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
    2. Connect the fuel hose, and install the fuel suction with pump and gauge tube to the fuel tank.
      GTY617672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to bend the arm of the fuel sender gauge.
      • When connecting the fuel hose, do not forcibly pull the hose.
  18. INSTALL FUEL TANK VENT TUBE SET PLATE 
    1. Install the No. 2 fuel tank protector and set plate with the 8 bolts.
      GTY655488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Align the protrusion of the set plate with the cutout of the fuel suction with pump and gauge tube.

    2. Install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips.
      GTY148219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      GTY678926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Check that there are no scratches or foreign objects on the connecting parts.
      • Check that the fuel tube joint is 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.
  19. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER 
    GTY634221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the 2 connectors.
    2. Install the service hole cover with new butyl tape.
  20. INSTALL FUEL SENDER GAUGE ASSEMBLY 
    1. Install a new gasket and the sender gauge to the fuel tank with the 5 screws.
      GTY634124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

  21. INSTALL REAR FLOOR SERVICE HOLE COVER 
    GTY634222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the fuel sender gauge connector.
    2. Install the service hole cover with new butyl tape.
  22. INSTALL REAR NO. 1 AND NO. 2 SEAT ADJUSTER ASSEMBLY 
  23. INSTALL SERVICE PLUG GRIP 

    (Refer to INSTALLATION [09/2015 - ] )

  24. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [09/2015 - ] ).

  25. INSTALL BATTERY SERVICE HOLE COVER LH 

    Refer to PROCEDURE - Step 13

  26. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  27. ADD FUEL 
  28. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

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