Fuel Tank: Installation: Installation

1. Install new No. 1 fuel tank cushions onto the fuel tank.
   Fig 1: Locating No. 1 Fuel Tank Cushion (4WD)

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1. Install new No. 3 fuel tank cushions onto the fuel tank.
   Fig 2: Locating No. 3 Fuel Tank Cushion (4WD)

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1. Install new fuel tank cushions onto the fuel tank.
   Fig 3: Locating Fuel Tank Cushion (2WD)

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1. Install the fuel tank vent hose.
   Fig 4: View Of Fuel Tank Vent Hose (4WD)

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1. Install the fuel tank vent hose onto the fuel tube clamp.
   Fig 5: Locating Fuel Tank Clamp

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1. Install the fuel tank main tube onto the fuel tank.
   Fig 6: Locating Fuel Tank Main Tube

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1. Set the fuel tank on a transmission jack.
2. Operate the transmission jack, then install the fuel tank into the vehicle.
   Fig 7: Holding Fuel Tank With Transmission Jack

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3. Install the 2 No. 1 fuel tank bands with the 4 bolts.
   Fig 8: Remove/Install No. 1 Fuel Tank Bands And Bolts (4WD)

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

1. Set the fuel tank on a transmission jack.
2. Operate the transmission jack, then install the fuel tank into the vehicle.
   Fig 9: Holding Fuel Tank With Transmission Jack

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3. Install the 2 No. 1 fuel tank bands with the 4 bolts.
   Fig 10: Remove/Install No. 1 Fuel Tank Bands And Bolts (2WD)

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

1. Connect the fuel tank filler pipe hose to the fuel tank.
   Fig 11: Connecting Fuel Tank To Filler Pipe Hose To Fuel Tank

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   NOTE:

   Make sure that the hose clamp is facing the correct direction when installing.

2. Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
   Fig 12: View Of Fuel Tank Filler Pipe Cover Claw

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1. Connect the fuel tank main tube.
   Fig 13: Connecting The Fuel Tank Main Tube

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   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
      NOTE:

      • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.

1. Connect the breather tube fuel hose.
   Fig 14: Locating Breather Tube Fuel Hose

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2. Connect the breather tube fuel hose.
   Fig 15: Connecting Breather Tube Fuel Hose

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   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
      NOTE:

      • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
      • After connecting the breather tube fuel hose, check that the fuel pump tube is securely connected by pulling on the fuel tube connector and pipe.
   2. Install the checker onto the pipe.

1. Connect the fuel tank vent hose.
   Fig 16: Connecting Fuel Tube Connector (Quick Type C)

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   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
   2. Slide the retainer of the fuel tube connector to lock the claws as shown in the illustration.
      NOTE:

      • Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tube connector.

HINT: 

• Refer to INSTALLATION - Step 1 for 4WD
• Refer to INSTALLATION - Step 1 for 2WD

1. Install the fuel tank protector sub-assembly with the 4 bolts and 2 nuts.
   Fig 17: Locating Fuel Tank Protector Fasteners (4WD)

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

1. Install the fuel tank protector sub-assembly with the 4 bolts.
   Fig 18: Locating Fuel Tank Protector Fasteners (2WD)

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

1. Install the parking brake cables with the 4 bolts.
   Fig 19: Locating Parking Brake Cables With Bolts

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

HINT: 

Refer to INSTALLATION - Step 10

HINT: 

Refer to INSTALLATION - Step 9

1. Install the fuel suction tube assembly to the fuel tank assembly. Refer to INSTALLATION .