Toyota Yaris: Fuel Tank / Installation

INSTALLATION

PROCEDURE

1. INSTALL CHARCOAL CANISTER OUTLET HOSE

(a) Engage the clamp to install the charcoal canister outlet hose to the fuel tank assembly.

2. INSTALL FUEL TANK ASSEMBLY

CAUTION:

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

(a) Set the fuel tank assembly on an engine lifter.

NOTICE:

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

(b) Using the engine lifter, slowly raise the fuel tank assembly, and temporarily install the fuel tank assembly, fuel tank band RH and fuel tank band LH with the 4 bolts.

(c) Tighten the 4 bolts in the order shown in the illustration. Torque: 45 N·m {459 kgf·cm, 33 ft·lbf} NOTICE: Be careful not to drop the fuel tank assembly. When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.

3. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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4. CONNECT NO. 6 FUEL TANK BREATHER TUBE

(a) Connect the No. 6 fuel tank breather tube.

5. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY

(a) Connect the fuel tank filler pipe sub-assembly.

6. INSTALL FUEL TANK TO FILLER PIPE HOSE

(a) Install the fuel tank to filler pipe hose to the fuel tank assembly and tighten the hose clamp.

7. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Install the fuel tank main tube sub-assembly to the fuel pipe.

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8. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

(a) Install the No. 1 fuel evaporation tube sub-assembly to the fuel pipe.

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

(a) Install the No. 1 fuel tank protector sub-assembly with the 4 clips.

10. INSTALL NO. 2 FUEL TANK PROTECTOR

(a) a. Install the No. 2 fuel tank protector with the 4 clips and nut.

Torque:

10.5 N·m {107 kgf·cm}

11. INSTALL DIFFERENTIAL CARRIER ASSEMBLY

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12. INSTALL FUEL TANK VENT TUBE ASSEMBLY

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13. INSTALL FUEL PUMP GAUGE RETAINER

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14. INSTALL NO. 1 FUEL TUBE CLAMP

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15. INSTALL REAR FLOOR SERVICE HOLE COVER (for RH Side)

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16. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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17. ADD FUEL