Installation

2UR-FSE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
(a) Install the fuel tank protector to the fuel tank.
2. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY






(a) Install the fuel tube 6 clamps.
(b) Install the fuel tank main tube to the fuel tank with the 6 clamps.
3. INSTALL FUEL TANK RETURN VENT TUBE






(a) Install the fuel tank return vent tube to the fuel tank.
4. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY






(a) Install the vent hose to the fuel tank.
- Check for damage or foreign matter around the connecting parts of the vent hose and fuel tank.
- After connecting, check that the vent hose and the valve are securely connected by pulling on them.

5. INSTALL FUEL SUCTION TUBE SUB-ASSEMBLY






(a) Install the fuel suction tube.
HINT: Push the parts together firmly until a "click" sound is heard.
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

6. INSTALL FUEL TANK WIRE






(a) Attach the 6 clamps of the fuel tank wire to install the wire to the fuel tank.
7. INSTALL FUEL TANK PRESSURE SENSOR
(a) Install the fuel tank pressure sensor Installation.
8. INSTALL FUEL TANK ASSEMBLY
(a) Set the fuel tank on a mission jack and raise the fuel tank.
NOTE: Do not allow the fuel tank to contact the vehicle, especially the differential.

(b) Connect the fuel tank to the fuel filler pipe and slide the filler pipe clamp.









- Insert the filler pipe into the fuel tank with their axes aligned. If not aligned, the insertion load increases.
- Do not twist or forcefully insert the filler pipe.
- After securely inserting the filler pipe into the fuel tank, attach the clamp. At this time, securely insert the clamp into the slit.





(c) Temporarily install the 2 fuel tank bands with the 4 bolts.
(d) Tighten the bolts in the front.
Torque: 39 Nm (408 kgf-cm, 30 ft-lbf)






(e) Using SST, a torque wrench and union nut wrench, tighten the bolts in the rear.
SST: 09961-00950
without SST - Torque: 39 Nm (408 kgf-cm, 30 ft-lbf)
with SST - Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
- Use a torque wrench with a fulcrum length of 180 mm (7.09 in).
- Make sure union nut wrench, SST and torque wrench are connected in a straight line.

9. CONNECT FUEL TANK WIRE






(a) Connect the fuel vapor containment valve connector and attach the 2 clamps.
10. CONNECT FUEL SUCTION TUBE SUB-ASSEMBLY






(a) Connect the fuel suction tube.
HINT: Push the parts together firmly until a "click" sound is heard.
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

11. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY






(a) Connect the fuel tank vent hose.
HINT: Push the parts together firmly until a "click" sound is heard.
- Before installing the hose connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

12. CONNECT FUEL TANK RETURN VENT TUBE






(a) Connect the fuel tank return vent tube.
HINT: Push the parts together firmly until a "click" sound is heard.
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

13. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY






(a) Connect the fuel tank main tube LH.
HINT: Push the parts together firmly until a "click" sound is heard.
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.





(b) Connect the fuel tank main tube RH.
HINT: Push the parts together firmly until a "click" sound is heard.
- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connecting, check if the connectors and pipes are securely connected by trying to pull them apart.

14. INSTALL FUEL TANK PROTECTOR BRACKET SIDE






(a) Install the protector with the 2 nuts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
15. INSTALL FUEL TANK FILLER PIPE PROTECTOR






(a) Install the tank protector with the 2 clips and 2 nuts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
16. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
(a) Install the propeller with center bearing shaft Installation.
17. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
(a) Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.






(b) Connect the fuel hose, and install the fuel suction with pump and gauge tube to the fuel tank.
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel hose, do not forcibly pull the hose.

18. INSTALL FUEL TANK VENT TUBE SET PLATE






(a) Install the No. 2 fuel tank protector and set plate with the 8 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
HINT: Align the protrusion of the set plate with the cutout of the fuel suction with pump and gauge tube.

(b) Install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips.









- Check that there are no scratches or foreign objects on the connecting parts.
- Check that the fuel tube joint is inserted securely.
- Check that the tube joint clips are on the collars of the fuel tube joints.
- After installing the tube joint clips, check that the fuel tube joints have not been pulled off.





19. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
(a) Connect the 2 connectors.
(b) Install the service hole cover with new butyl tape.
20. INSTALL FUEL SENDER GAUGE ASSEMBLY






(a) Install a new gasket and the sender gauge to the fuel tank with the 5 screws.
Torque: 1.5 Nm (15 kgf-cm, 13 in-lbf)






21. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the fuel sender gauge connector.
(b) Install the service hole cover with new butyl tape.
22. INSTALL REAR NO. 2 SEAT ADJUSTER ASSEMBLY (for Power Seat)
(a) Install the rear No. 2 seat adjuster assembly Installation.
23. INSTALL REAR NO. 2 SEAT ADJUSTER ASSEMBLY (for Ottoman)
(a) Install the rear No. 2 seat adjuster assembly Installation.
24. INSTALL REAR NO. 1 SEAT ADJUSTER ASSEMBLY (for Power Seat)
(a) Install the rear No. 1 seat adjuster assembly Installation.
25. INSTALL REAR NO. 1 SEAT ADJUSTER ASSEMBLY (for Ottoman)
(a) Install the rear No. 1 seat adjuster assembly Installation.
26. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type) Installation

27. INSTALL SERVICE PLUG GRIP Installation

28. INSTALL BATTERY SERVICE HOLE COVER Hybrid Battery Service Switch

29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

30. INSTALL BATTERY SERVICE HOLE COVER LH Battery

31. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY

32. ADD FUEL
33. INSPECT FOR FUEL LEAK Testing and Inspection