From 08/2009

2GR-FXE FUEL: FUEL TANK: INSTALLATION

1. INSTALL FUEL TANK CUSHION

(a) Install 8 new fuel tank cushions to the fuel tank.





2. INSTALL CLAMP

(a) Install the 2 fuel tube clamps of the fuel tank main tube to the fuel tank.





(b) Install the grommet to the fuel tank.





3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Install the fuel tank main tube to the clamp.





4. INSTALL FUEL TANK WIRE

(a) Connect the 4 clamps to install the fuel tank wire.





5. INSTALL FUEL TANK SOLENOID MAIN VALVE ASSEMBLY

(a) Connect the fuel tank vent hose to the fuel tank.





(b) Install the 2 nuts to the fuel tank solenoid main valve assembly.





Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(c) Connect the connector and clamp.





6. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

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

7. INSTALL FUEL TANK ASSEMBLY

(a) Set the fuel tank on a transmission jack.





Text in Illustration





(b) Operate the engine lifter, and install the fuel tank to the vehicle.

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

(c) Connect the fuel tank inlet pipe with the tube connector and clamp.

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





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

8. CONNECT BREATHER LOWER TUBE

(a) Connect the breather lower tube.





Text in Illustration





(1) Push in the tube connector to the pipe until the tube connector makes a "click" sound.

NOTICE:
* Check for damage or foreign objects on the connected part of the fuel pipe.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(b) Install the connector cover to the pipe.

9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Connect the fuel tank main tube sub-assembly.





Text in Illustration





(1) Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.

NOTICE:
* Check for damage or foreign objects on the connected part.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
10. CONNECT CHARCOAL CANISTER FUEL HOSE

(a) Align the quick connector with the pipe, then push in the quick connector until the retainer makes a "click" sound to connect the charcoal canister fuel hose to the charcoal canister assembly.





NOTICE:
* Check for 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 that the charcoal canister fuel hose is securely connected by pulling on the quick connector.
11. CONNECT FUEL TANK WIRE

(a) Connect the fuel tank wire connectors, and install them to the bracket.





12. INSTALL FRONT CENTER FLOOR COVER Installation

13. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY

(a) Install the No. 3 parking brake cable assembly with the nut.





Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

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

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





15. INSTALL NO. 3 FRONT FLOOR HEAT INSULATOR

(a) Install the No. 3 front floor heat insulator with the 4 nuts.





Torque : 4.9 Nm (50 kgf-cm, 43 in-lbf)

16. INSTALL CENTER EXHAUST PIPE ASSEMBLY

HINT
Installation

17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

18. INSTALL REAR DECK FLOOR BOX Installation

19. ADD FUEL

20. INSPECT FOR FUEL LEAK Testing and Inspection

21. INSPECT FOR EXHAUST GAS LEAK