FUEL TANK INSTALLATION


  1. INSTALL NO. 1 FUEL TANK CUSHION


    1. Install 8 new No. 1 fuel tank cushions to the fuel tank assembly.

  2. INSTALL FUEL MAIN TUBE SUPPORT


    1. Install the fuel main tube support to the fuel tank assembly with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Install the fuel tank main tube sub-assembly to the fuel main tube support.

  4. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. A01EMAQE01
      Text in Illustration
      *a 120°
      A01EMIT Upper

      Install the fuel tank to filler pipe hose to the fuel tank assembly and tighten the clamp to secure it.

      Tech Tips

      Make sure the clamp bolt is within the area shown in the illustration.

  5. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. A01EK8PE02
      Text in Illustration
      *a Retainer
      *b O-ring
      *c Fuel Tube Connector
      *d Fuel Pipe
      A01EM1I Push
      A01EMIT Push in

      Install the fuel tank breather tube sub-assembly to the fuel tank assembly.

      Note

      Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


      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 engine oil to the tip of the fuel pipe and reinsert it.

      2. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

  6. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY


    1. A01EM3HE02
      Text in Illustration
      *a Retainer
      *b Claw
      A01EM1I Push
      A01EMIT Push in

      Push the fuel tank vent hose sub-assembly onto the fuel tank assembly and push in the retainer to engage the 2 claws.

      Note


      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tank vent hose sub-assembly and fuel tank assembly before performing this work.

      • After connecting the fuel tank vent hose sub-assembly, check that the fuel tank vent hose sub-assembly is securely connected by pulling on it.

  7. INSTALL FUEL TANK ASSEMBLY


    1. Install the 4 clip nuts to the fuel tank assembly.

    2. A01EM9S

      Install the 2 fuel tank band sub-assemblies with the 2 straight pins as shown in the illustration.

    3. Set the fuel tank assembly on an engine lifter.

    4. Using the engine lifter, slowly raise the fuel tank assembly, and then install the fuel tank assembly with the 2 fuel tank band sub-assemblies with the 2 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

      Note


      • Do not drop the fuel tank assembly.

      • When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the other surrounding parts.

    5. A01EJI9E02
      Text in Illustration
      *a 120°
      A01EMIT Upper

      Connect the fuel tank to filler pipe hose and tighten the clamp to secure it.

    6. A01EIWCE01
      Text in Illustration
      *a Retainer
      *b O-ring
      *c Fuel Tube Connector
      *d Fuel Pipe
      A01EM1I Push
      A01EMIT Push in

      Connect the fuel tank breather tube sub-assembly.

      Note

      Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


      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 engine oil to the tip of the fuel pipe and reinsert it.

      2. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

    7. Engage the 2 clamps to connect the fuel tank vent hose sub-assembly.

    8. A01EJ41E02
      Text in Illustration
      *a Retainer
      *b Claw
      A01EM1I Push
      A01EMIT Push in

      Push the fuel tank vent hose sub-assembly onto the charcoal canister assembly and push in the retainer to engage the 2 claws.

      Note


      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tank vent hose sub-assembly and charcoal canister assembly before performing this work.

      • After connecting the fuel tank vent hose sub-assembly, check that the fuel tank vent hose sub-assembly is securely connected by pulling on it.

    9. A01EL1EE02
      Text in Illustration
      *a Retainer
      *b Fuel Pipe
      *c Fuel Tube Connector
      *d O-ring
      *e Claw
      A01EM1I Push
      A01EMIT Push in

      Connect the fuel tank main tube sub-assembly.

      Note

      Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


      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 engine oil 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.

  8. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 3 parking brake cable assembly with the bolt and nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  9. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 2 parking brake cable assembly with the bolt and nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  10. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. Install the No. 1 fuel tank protector sub-assembly with the 4 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  11. INSTALL FRONT FLOOR BRACE LH


    1. Install the front floor brace LH with the bolt and 2 nuts.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

  12. INSTALL FRONT FLOOR BRACE RH


    1. Install the front floor brace RH with the bolt and 2 nuts.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

  13. INSTALL ELECTRO MAGNETIC CONTROL COUPLING SUB-ASSEMBLY (for AWD)


    1. Using a scraper and wire brush, remove the seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      Note


      • Do not damage the contact surface.

      • Be sure to completely remove all seal packing from the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

      • Do not allow the removed seal packing to enter the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

    2. Using a non-residue solvent, remove grease and oil from the contact surfaces of the rear differential carrier assembly and the electro magnetic control coupling sub-assembly.

      Note

      Do not damage the contact surface.

    3. A01ELJ4E02
      Text in Illustration
      *a 20 mm (0.787 in.)
      *b 1.0 mm (0.0394 in.)
      *c 1.4 mm (0.0551 in.)
      *d 3.0 mm (0.118 in.)
      *d 2.0 mm (0.0787 in.)

      Apply seal packing to the areas indicated in the illustration of the rear differential carrier assembly.

      Seal packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

      Note


      • Start applying seal packing within range (A).

      • Make sure that the clearance from the center of the bead is within 1 mm (0.0394 in.).

      • Apply seal packing in a continuous bead 2 to 3 mm (0.0787 to 0.118 in.) in diameter.

      • If there is an area where seal packing is not applied in a continuous bead, be sure to apply seal packing by overlapping the ends of the bead at least 10 mm (0.394 in.).

      • Stop applying seal packing after allowing it to overlap with the beginning of the bead by at least 10 mm (0.394 in.) within range (A) in the illustration.

      • Install the electro magnetic control coupling sub-assembly within 10 minutes after applying seal packing. If the electro magnetic control coupling sub-assembly is not installed within 10 minutes after applying seal packing, completely remove and then reapply seal packing.

      • After installing the electro magnetic control coupling sub-assembly, do not immediately add oil or drive the vehicle for at least 1 hour.

    4. A01EMPL

      Install the electro magnetic control coupling sub-assembly with the 4 bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Note


      • Do not damage the diaphragm oil seal.

      • Do not damage the contact surface of the rear differential carrier assembly and electro magnetic control coupling sub-assembly.

  14. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

    Click here

  15. INSTALL CENTER EXHAUST PIPE ASSEMBLY

    Click here

  16. ADD FUEL

  17. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. A01EJWP

      Install the fuel sender gauge assembly to the fuel tank with the 6 bolts.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

      Note

      Be careful not to bend the arm of the fuel sender gauge assembly.

  18. INSTALL REAR NO. 2 FLOOR SERVICE HOLE COVER


    1. A01EKZO

      Connect the fuel sender gauge connector.

    2. Install the rear No. 2 floor service hole cover with new butyl tape.

  19. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

    Click here

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  21. INSPECT FOR EXHAUST GAS LEAK