FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B0028QJC01
      *a Protrusion
      *b Paint Mark (White)

      Install the fuel tank to filler pipe hose to the fuel tank sub-assembly, and tighten the clamp to secure the hose.

      Tech Tips

      Make sure the hose clamp is oriented as shown in the illustration.

  2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

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  3. INSTALL FUEL TANK CLAMP

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  4. INSTALL NO. 2 FUEL TANK CUSHION


    1. Install the 2 new No. 2 fuel tank cushions to the fuel tank sub-assembly.

  5. INSTALL NO. 3 FUEL TANK CUSHION


    1. Install a new No. 3 fuel tank cushion to the fuel tank sub-assembly.

  6. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. Install the No. 1 fuel tank heat insulator with the 4 No. 2 fuel tank brackets.

    2. Install the nut.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  7. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank sub-assembly on an engine lifter and raise the fuel tank sub-assembly.

      Note

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

    2. Fold back approximately half of each cushion so that the wire harness can be installed in the step below.

    3. Attach the wire harness to the 6 clamps and connect the fuel sender gauge assembly connector.

      Note

      Be careful not to cut the wire harness.

    4. Install the 2 fuel tank bands with the 2 fuel tank band pins and 2 clips.

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

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

  8. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B0028M5C01
      *a Protrusion
      *b Paint Mark (Yellow)
      *c 0 to 3 mm (0 to 0.118 in.)
      *d 2 to 7 mm (0.0787 to 0.276 in.)

      Connect the fuel tank to filler pipe hose to the fuel tank filler pipe sub-assembly, and tighten the clamp to secure the hose.

      Tech Tips

      Make sure the hose clamp is oriented as shown in the illustration.

  9. CONNECT FUEL TANK BREATHER HOSE


    1. B0028Y2C01
      *a Paint Mark
      *b Top of Vehicle

      Connect the fuel tank breather hose to the fuel tank filler pipe sub-assembly, and slide the clamp to secure the hose.

      Tech Tips

      Make sure the hose clamp is oriented as shown in the illustration.

    2. Attach the fuel tank breather hose to the clamp.

  10. CONNECT FUEL MAIN TUBE AND FUEL RETURN TUBE


    1. Connect the fuel tank main tube sub-assembly and fuel tank return tube, vent line tube.

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  11. INSTALL NO. 3 FUEL TUBE CLAMP


    1. Install the No. 3 fuel tube clamp to the fuel tube with the 3 claws.

  12. INSTALL NO. 1 FUEL TANK PROTECTOR (for 4WD and Pre-Runner)


    1. Install the No. 1 fuel tank protector to the fuel tank sub-assembly with the 5 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  13. INSTALL FUEL TANK CAP ASSEMBLY

  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  15. INSPECT FOR FUEL LEAK

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