Installation

2GR-FSE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL NO. 2 FUEL TANK PROTECTOR





(a) Install the No. 2 fuel tank protector to the fuel tank assembly.
2. INSTALL FUEL TANK CUSHION





(a) Install 11 new fuel tank cushions shown in the illustration.
3. INSTALL FUEL TANK VENT HOSE





(a) Connect the fuel tank vent hose to the fuel tank.
4. INSTALL FUEL TANK TO FILLER PIPE HOSE





(a) Install the fuel tank to filler pipe hose to the fuel tank with the clamp.
(b) Tighten the hose clamp bolt.
5. INSTALL FUEL TUBE SUB-ASSEMBLY





(a) Install the edge protector with the 2 clamps.





(b) Install a fuel tank main tube and fuel tank return vent tube with the clamp.
6. INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
(a) Install a new gasket to the No. 1 fuel tank breather tube sub-assembly.





(b) Install the No. 1 fuel tank breather tube sub-assembly with the 4 bolts.
Torque: 1.5 Nm (15 kgf-cm, 13 in-lbf)
7. INSTALL FUEL TANK ASSEMBLY





(a) Set a engine lifter to the fuel tank and lift it up.
(b) Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
8. CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY





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

9. CONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY





(a) Connect the No. 3 fuel hose sub-assembly with the clip.
(b) Connect the fuel hose clamp.
10. CONNECT FUEL TANK TO FILLER PIPE HOSE





(a) Connect the fuel tank to filler pipe hose with the clamp.
11. CONNECT FUEL TUBE SUB-ASSEMBLY





(a) Connect the fuel tank main tube (RH side).
(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.





(b) Connect the fuel tank return vent tube.
(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.





(c) Connect the fuel tank main tube (LH side).
(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.





12. CONNECT PARKING BRAKE CABLE ASSEMBLY
(a) Connect the 4 clamps.
(b) Connect the 2 parking brake cables with the 4 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)for bolt A
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)for bolt B
13. INSTALL REAR SUSPENSION MEMBER BRACE LH





(a) Install the suspension member brace lower LH with the 4 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)
14. INSTALL REAR SUSPENSION MEMBER BRACE RH





(a) Install the suspension member brace lower RH with the 4 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)
15. INSTALL REAR FLOOR SIDE MEMBER COVER LH
16. INSTALL REAR FLOOR SIDE MEMBER COVER RH
17. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR Installation
18. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
HINT:
Installation procedure of the No. 1differential support protector is the same as that of the No. 2 differential support protector.

19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
HINT:
Installation.

20. INSTALL FRONT EXHAUST PIPE ASSEMBLY
HINT:
Installation.

21. INSTALL FUEL SENDER GAUGE ASSEMBLY





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





(b) Connect the fuel sender gauge connector.
22. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Installation
23. ADD FUEL
24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation
25. INSPECT FOR FUEL LEAK Testing and Inspection
26. INSPECT FOR EXHAUST GAS LEAK
27. INSTALL REAR FLOOR SERVICE HOLE COVER





(a) Install the service hole cover with new butyl tape.
28. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER Installation
29. INSTALL REAR SEAT CUSHION ASSEMBLY Installation