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Home >> Lexus >> 2009 >> GS 450h V6-3.5L (2GR-FSE) Hybrid >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Tank >> Service and Repair >> Installation

Installation








2GR-FSE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL FUEL TANK CUSHION





(a) Install the tank cushion and tank protector.





(b) Install the 11 tank cushions.
2. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY





(a) Install the vent hose to the fuel tank.
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 connection, check if the connectors and pipes are securely connected by trying to pull them apart.

3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Attach the 2 claws to the claw holes and install a new edge protector.





(b) Install the clamp, fuel tank main tube and return tube.
4. INSTALL FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY





(a) Install a new gasket and the canister tube with the 4 screws.
Torque: 1.5 Nm (15 kgf-cm, 13in-lbf)
5. INSTALL FUEL TANK WIRE





(a) Install the tank wire with the 7 clamps.
6. REMOVE FUEL TANK VENT TUBE SET PLATE Installation
7. INSTALL FUEL TANK PRESSURE SENSOR Installation
8. INSTALL NO. 3 FUEL TANK PROTECTOR Installation
9. INSTALL FUEL TANK SUB-ASSEMBLY
(a) Set the fuel tank on a mission jack and raise the fuel tank.
(b) Install the clamp, and connect the fuel filler pipe to the fuel tank.








- 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) Raise the mission jack.





(d) Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29ft-lbf)





(e) Tighten the 2 fuel filler pipe bolts.
Torque: 18 Nm (184 kgf-cm, 13ft-lbf)
10. CONNECT FUEL TANK WIRE





(a) Connect the fuel vapor containment valve connector and 2 clamps.
11. CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY





(a) Connect the canister tube and install the clamp.
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 connection, check if the connectors and pipes are securely connected by trying to pull them apart.

12. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY





(a) Connect the fuel tank vent hose and install the clamp.
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 connection, 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 connection, 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 connection, check if the connectors and pipes are securely connected by trying to pull them apart.

14. CONNECT FUEL TANK RETURN VENT TUBE





(a) Connect the fuel return vent tube and install the retainer.
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 connection, check if the connectors and pipes are securely connected by trying to pull them apart.

15. CONNECT PARKING BRAKE CABLE ASSEMBLY





(a) Connect the 2 parking brake cables to the parking brake equalizer.
(b) Install the 2 parking brake cables with the 4 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53in-lbf)for bolt A
Torque: 19 Nm (193 kgf-cm, 14ft-lbf)for bolt B
(c) Attach the 2 parking brake cables to the 4 clamps.
16. INSTALL REAR SUSPENSION MEMBER BRACE RH





(a) Install the suspension member brace with the 4 bolts.
Torque: 19 Nm (193 kgf-cm, 14ft-lbf)
17. INSTALL REAR SUSPENSION MEMBER BRACE LH





(a) Install the suspension member brace with the 4 bolts.
Torque: 19 Nm (193 kgf-cm, 14ft-lbf)
18. INSTALL REAR FLOOR SIDE MEMBER COVER LH





(a) Install the member cover with the 3 bolts.
19. INSTALL REAR FLOOR SIDE MEMBER COVER RH





(a) Install the member cover with the 3 bolts.
20. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR





(a) Install the differential supporter with the 2 nuts.
21. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
(a) Install the differential supporter with the 2 nuts.
22. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation
23. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY Installation
24. ADJUST NO. 2 AND NO. 3 JOINT ANGLE Installation
25. INSTALL OUTSIDE AIR GUIDE PLATE RH





(a) Install the plate with the 4 nuts.
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)
26. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR





(a) Install the heat insulator with the 5 nuts.
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)
27. INSTALL FRONT FLOOR COVER CENTER LH





(a) Install the floor cover center with the 3 nuts.
28. INSTALL FRONT FLOOR COVER CENTER RH





(a) Install the floor cover center with the 3 nuts.
29. INSTALL EXHAUST PIPE ASSEMBLY
(a) Install the exhaust pipe Installation.
30. INSTALL FUEL SENDER GAUGE ASSEMBLY





(a) Install the sender gauge with the 5 screws.
Torque: 1.5 Nm (15 kgf-cm, 13in-lbf)
31. INSTALL REAR FLOOR SERVICE HOLE COVER





(a) Connect the fuel sender gauge connector.
(b) Install the service hole cover with new butyl tape.
32. 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 set the fuel suction with pump and gauge.
- Be careful not to bend the arm of the fuel sender gauge.
- When connecting the fuel hose, do not forcibly pull the hose.





(c) Install the set plate with the 8 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53in-lbf)
HINT: Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.

(d) Install the 2 fuel tank tubes 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.

33. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER





(a) Connect the 2 connectors.
(b) Install the service hole cover with new butyl tape.
34. INSTALL ROOM NO. 3 PARTITION PAD





(a) Install the partition pad with the clip.
35. INSTALL REAR SEAT CUSHION ASSEMBLY Installation
36. INSTALL SERVICE PLUG GRIP Installation
37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
38. CHECK FOR FUEL LEAKS Testing and Inspection
39. PERFORM INITIALIZATION
(a) Perform initialization Repair Instruction - Initialization.
NOTICE:
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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