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Home >> Toyota >> 2007 >> RAV4 Base, 2.4 D, AWD >> Repair and Diagnosis >> Engine Performance >> Fuel Delivery >> Engine Fuel System (2AZ-FE) >> Fuel Tank >> Installation
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Fuel Tank: Installation

  1. INSTALL FUEL TANK ASSEMBLY 
    1. Set the fuel tank on a mission jack.
    2. Lift up the mission jack.
    3. Fold back the 2 cushion rubbers.
    4. Connect the fuel pump connector and sender gauge connector to the fuel tank.
      NOTE: Be careful not to cut the wirings.
    5. Attach the wire harness to the 4 clamps.
      Fig 1: Attaching Wire Harness To Clamps
      G04485509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 3 fuel tank bands with the 6 bolts.

      Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) 

  2. INSTALL FUEL TANK FILLER PIPE 
    1. Install the filler pipe with the 2 bolts.

      Torque: 23.5 N.m (240 kgf.cm, 17 ft.lbf) 

    2. Install the filler pipe protector with the 3 bolts.
      Fig 2: Installing Filler Pipe Protector With Bolts
      G04485510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. CONNECT FUEL TANK TO FILLER PIPE HOSE 
    1. Connect the filler pipe hose to the fuel tank.
      Fig 3: Connecting Filler Pipe Hose To Fuel Tank
      G04485511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT FUEL TANK BREATHER HOSE 
    1. Connect the fuel tank breather hose to the fuel tank.
      NOTE:
      • Before installing the tube connector to the pipe, check the connector for damage and foreign matter.
      • Check that the connector and pipe is securely connected by trying to pull them apart.
  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY 
    NOTE: Before installing the tube connector to the pipe, check the connector for damage and foreign matter.
    Fig 4: Connecting Fuel Tank Breather Hose To Fuel Tank
    G04485512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the main tube connector to the pipe. Push the 2 parts together firmly until a "click" sound is heard.
      NOTE: Check that the connector and pipe are securely connected by trying to pull them apart.
    2. Connect the EVAP hose to the fuel tank.
      Fig 5: Connecting EVAP Hose To Fuel Tank
      G04485513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 FLOOR UNDER COVER 
    1. Install the floor cover with the clip and 2 nuts.
  7. INSTALL FRONT FLOOR COVER 
    1. Install the floor under cover with the 3 clips, bolt and nut.
      Fig 6: Installing Floor Under Cover With Clips, Bolt And Nut
      G04485514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY 
    1. Install the parking brake cable with the 2 bolts.
      Fig 7: Installing Parking Brake Cable With Bolts
      G04485515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FUEL TANK CAP 
  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  11. INSPECT FOR FUEL LEAKS (See  CHECK FOR FUEL LEAKAGE  ). 
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