Up to 08/2009

2GR-FE FUEL: FUEL TANK: INSTALLATION

1. INSTALL TANK SUCTION TUBE SUPPORT

(a) Install a new tank suction tube support as shown in the illustration.





Text in Illustration





2. INSTALL FUEL TANK CUSHION SET

(a) Install the fuel tank cushion sets and No. 5 fuel tank cushions.





Text in Illustration





3. INSTALL FUEL TANK TO FILLER PIPE HOSE

(a) Install the fuel tank to filler pipe hose with the hose clamp.





4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Install the fuel pump tube, and engage the 2 claws.





Text in Illustration





5. INSTALL NO. 2 FUEL TANK SIDE PLATE

(a) Install a new No. 2 fuel tank side plate.





6. INSTALL FUEL TANK ASSEMBLY

(a) Set the fuel tank onto a engine lifter.





(b) Operating the engine lifter, install the fuel tank.

NOTICE:
Slowly raise the lifter so as not to drop the fuel tank assembly.

(c) Install the 2 fuel tank bands with the 4 bolts.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

(d) Install the rear fuel tank bracket LH with the bolt and nut.





Bolt - Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

Nut - Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

(e) Tighten the nut.





Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)

(f) Align the matchmarks and install the fuel tank to filler pipe hose to the fuel tank.





(g) Install the hose clamp within the range shown in the illustration.

(h) Connect the fuel tank vent hose.





(1) Push the quick connector and push in the retainer to lock the claws.

NOTICE:
* Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this work.
* After connecting the charcoal canister fuel hose, check if the quick connector and the pipe are securely connected by pulling on them.
(i) Connect the No. 3 fuel tank breather tube.





(1) Push the quick connector and push in the checker to lock the retainer.

NOTICE:
* Check if there is any damage or foreign objects on the connected part.
* After connecting, check if the quick connector and the pipe are securely connected by pulling on them.
(j) Connect the fuel tank main tube sub-assembly.





Text in Illustration





(1) Push the quick connector and push in the retainer to lock the claws.

NOTICE:
* Check if there is any damage or foreign objects on the connected part.
* After connecting, check if the quick connector and the pipe are securely connected by pulling on them.
7. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Install the No. 1 fuel tank protector sub-assembly with the 7 nuts.





Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(b) Install 3 new clips (A).

8. INSTALL CHARCOAL CANISTER PROTECTOR Installation

9. INSTALL FRONT CENTER FLOOR COVER

10. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

(a) Install the fuel suction tube assembly with pump and gauge Installation.

11. INSTALL REAR SUSPENSION MEMBER (for AWD)

(a) Install the rear suspension member Installation.

12. INSTALL TAIL EXHAUST PIPE ASSEMBLY (for 2WD) Installation

13. INSPECT FOR EXHAUST GAS LEAK (for 2WD)