Installation

2UR-GSE FUEL: FUEL TANK: INSTALLATION

1. INSTALL NO. 1 FUEL TANK PROTECTOR

(a) Install the No. 1 fuel tank protector to the fuel tank assembly.

2. INSTALL FUEL TANK CUSHION

(a) Install 11 new fuel tank cushions as shown in the illustration.

3. INSTALL FUEL TANK VENT HOSE

(a) Install the fuel tank vent hose with the clip.

4. INSTALL FUEL TANK TO FILLER PIPE HOSE

(a) Install the fuel tank to filler pipe hose to the fuel tank assembly with the clamp.

5. INSTALL FUEL TUBE SUB-ASSEMBLY

(a) Install the 2 tank bracket retainer sub-assemblies.

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

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 the fuel tank assembly onto an engine lifter.

(b) Raise the engine lifter so that the No.1 fuel tank breather tube sub-assembly can be connected. Connect the hose.

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

(c) Install the fuel tank assembly with the fuel tank bands and 4 bolts.

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

8. CONNECT FUEL TANK VENT HOSE

(a) Connect the fuel tank vent hose with the clamp.

9. CONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Connect the fuel tank to filler pipe hose with the clamp.

10. 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 matter 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.

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

(b) Install the bolt, loosen the grommet then install No. 4 fuel tank protector.

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

(c) Connect the 4 clamps.

(d) Connect the 2 parking brake cable assemblies 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

12. INSTALL REAR SUSPENSION REAR LOWER MEMBER BRACE LH Installation

13. INSTALL REAR SUSPENSION REAR LOWER MEMBER BRACE RH Installation

14. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

HINT
Installation.

15. INSTALL FRONT EXHAUST PIPE ASSEMBLY

HINT
Installation.

16. INSTALL NO. 2 FLOOR UNDER COVER Installation

17. INSTALL NO. 1 FLOOR UNDER COVER Installation

18. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR Installation

19. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR

HINT
Use the same procedure as for the No. 2 differential support protector.

20. INSTALL FUEL SENDER GAUGE

(a) Install the fuel sender gauge to the fuel tank with the 5 bolts.

Torque : 1.5 Nm (15 kgf-cm, 13 in-lbf)

NOTICE:
Be careful not to bend the arm of the fuel sender gauge.

(b) Connect the fuel sender gauge connector.

21. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Installation

22. ADD FUEL

23. 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.

24. INSPECT FOR FUEL LEAK Fuel System

25. INSPECT FOR EXHAUST GAS LEAK

26. INSTALL REAR FLOOR SERVICE HOLE COVER

(a) Install the service hole cover with new butyl tape.

27. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER Installation

28. INSTALL NO. 3 ROOM PARTITION PAD Installation

29. INSTALL REAR SEAT CUSHION ASSEMBLY Installation