Installation

2ZR-FXE FUEL: FUEL TANK: INSTALLATION

1. INSTALL FUEL TANK COVER VENT CASE SUB-ASSEMBLY

(a) Install 2 new fuel tank cover vent case sub-assemblies as shown in the illustration.





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2. INSTALL NO. 1 FUEL TANK CUSHION

(a) Install 3 new No. 1 fuel tank cushions as shown in the illustration.





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3. INSTALL NO. 3 FUEL TANK PROTECTOR

(a) Install the No. 3 fuel tank protector with the 2 nuts.

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

4. INSTALL FUEL TANK ASSEMBLY

(a) Support the fuel tank using an engine lifter.

(b) Raise the engine lifter, then install the fuel tank to the vehicle.

NOTICE:
* Do not drop the fuel tank.
* When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

(c) Tighten the 4 set bolts of the 2 fuel tank bands.

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

(d) Connect the parking brake cable assembly with the 2 bolts.

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

5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Push in the fuel tank main tube connector to the pipe and push up the retainer so that the claws engage.





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NOTICE:
* Check that there are no scratches or foreign matter around the connected parts of the fuel tube connector and pipe before starting this step.
* After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.

6. CONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Connect the fuel tank to filler pipe hose to the fuel tank, then fit it with the clamp as shown in the illustration.





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7. CONNECT FUEL TANK BREATHER TUBE

(a) Align the fuel tube connector with the pipe, push the fuel tube connector in until the retainer makes a "click" sound, then lock the cover of the connector.





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NOTICE:
* Check that there are no scratches or foreign matter around the connected parts of the fuel tube connector and pipe before starting this step.
* After connecting the fuel tank main tube sub-assembly, check that the fuel tank main tube sub-assembly is securely connected by pulling on the fuel tube connector.

8. CONNECT FUEL CUT-OFF TUBE

(a) Push in the fuel cut-off tube connector to the charcoal canister and push up the retainer so that the claws engage.





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NOTICE:
* Check that there are no scratches or foreign matter around the connected parts of the fuel cut-off tube connector and pipe before performing this work.
* After connecting the fuel cut-off tube, check that the fuel cut-off tube is securely connected by pulling the fuel cut-off tube connector and the charcoal canister.

9. INSTALL NO. 1 FUEL TANK PROTECTOR

(a) Install the No. 1 fuel tank protector with the 2 bolts and nut.

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

10. INSTALL REAR FLOOR SIDE MEMBER COVER LH (w/ Floor Under Cover)

(a) Install the rear floor side member cover LH with the 2 clips.





(b) Install the 2 bolts and nut.

11. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation

12. ADD FUEL

13. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

Installation

14. INSPECT FOR EXHAUST GAS LEAK