Installation [12/2019 - 10/2022]: Procedure

HINT: 

Perform this procedure only when replacement of the No. 1 fuel tank cushion is necessary.

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

HINT: 

Perform this procedure only when replacement of the No. 6 fuel tank cushion is necessary.

1. Install 3 new No. 6 fuel tank cushions to the fuel tank sub-assembly.

1. Install the No. 2 fuel tube clamp to the fuel tank breather tube sub-assembly.
2. Engage the clamp to install the fuel tank breather tube sub-assembly to the fuel tank sub-assembly.

1. Install the No. 2 fuel tank protector to the fuel tank sub-assembly with the clip.

1. Engage the clamp to install the No. 1 fuel tube clamp to the fuel tank sub-assembly.

1. Engage the 4 clamps to install the fuel tank evaporation vent tube sub-assembly to the fuel tank sub-assembly.

1. Engage the 3 clamps to install the fuel tank main tube sub-assembly to the fuel tank sub-assembly.

WARNING:

The fuel tank sub-assembly is very heavy. Be sure to follow the procedure described in the repair information, or the fuel tank sub-assembly may fall off the engine lifter.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the fuel tank sub-assembly on an engine lifter.
   NOTE:

   Using height adjustment attachments and plate lift attachments, keep the fuel tank sub-assembly horizontal.

2. Using the engine lifter, slowly raise the fuel tank sub-assembly, and then temporarily install the fuel tank sub-assembly, No. 1 fuel tank band sub-assembly and No. 2 fuel tank band sub-assembly with the 5 bolts.

   Bolt Length

   Bolt	Width Across Flats
   A	14 mm (0.551 in.)
   B	12 mm (0.472 in.)
   C	12 mm (0.472 in.) or 14 mm (0.551 in.)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • Be careful not to drop the fuel tank sub-assembly.
   • When installing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the surrounding parts.
3. Tighten the 5 bolts in the order shown in the illustration.
   Fig 1: Fuel Tank Sub-Assembly Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 45 N.m (459 kgf/cm, 33 ft.lbf) 

4. Connect the lower fuel tank filler pipe sub-assembly to the fuel tank filler pipe sub-assembly.

   Refer to PRECAUTION [12/2019 - 10/2022]

5. Connect the fuel tank breather tube sub-assembly to the fuel tank filler pipe sub-assembly.

   Refer to PRECAUTION [12/2019 - 10/2022]

6. for 2WD:
   1. Install the engine service cover assembly and rear main muffler heat insulator sub-assembly to the vehicle body with the nut.

      Torque: 4.9 N.m (50 kgf/cm, 43 in.lbf) 

1. Connect the fuel tank main tube sub-assembly to the fuel pipe.

   Refer to PRECAUTION [12/2019 - 10/2022]

1. Engage the clamp to connect the fuel tank evaporation vent tube sub-assembly to the canister (charcoal canister assembly).

   Refer to PRECAUTION [12/2019 - 10/2022]

Refer to INSTALLATION [12/2019 - 10/2022]

1. Install the No. 1 floor under cover with the 4 grommets (F), clip (C), clip (D) and clip (E).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Install the 4 bolts (A) and screw (B).

   Bolt 

   Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

1. Install the front floor cover LH with the 2 grommets (D) and clip (C).

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Install the 4 bolts (A) and 6 screws (B).

   Bolt 

   Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

Refer to INSTALLATION [12/2019 - 10/2022]