Installation

3UR-FE FUEL: FUEL TANK: INSTALLATION

1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR

(a) Install the No. 1 fuel tank heat insulator with the 4 clips.

(b) Install the fuel tube clamp to the No. 1 fuel tank heat insulator.

2. INSTALL FUEL TANK TO FILLER PIPE HOSE

(a) Install the fuel tank to filler pipe hose to the fuel tank as shown in the illustration.

HINT
* Align the fuel tank side mark with the hose side mark when installing the hose.
* Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

(a) Apply a light coat of gasoline or grease to a new gasket, and install it to the fuel tank.

(b) Install the fuel suction with pump and gauge tube into the fuel tank.

NOTICE:
* Be careful not to bend the arm of the fuel sender gauge.
* Align the protrusion of the fuel suction with pump and gauge tube with the groove of the fuel tank.

(c) Put the retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer 1 complete turn by hand.

(d) Set SST on the fuel pump gauge retainer.

SST : 09808-14030

HINT
* Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.
* Securely attach the claws of SST to the protrusions of the fuel pump gauge retainer and fix SST in place.
* Install SST while pressing the claws of SST against the fuel pump gauge retainer (toward the center of SST).

(e) Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank as shown in the illustration.

SST : 09808-14030

HINT
Fit the tips of SST onto the ribs of the retainer.

4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY

(a) Install the 2 fuel tank tubes and No. 1 fuel tube joint with the 3 tube joint clips.

NOTICE:
* Check that there are no scratches or foreign objects on the connecting parts.
* Check that the fuel tube joints are 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.

(b) Install the fuel tank main tube and fuel tank return tube to the fuel tank.

5. INSTALL FUEL TANK SUB-ASSEMBLY

(a) Set the fuel tank on a transmission jack and raise the fuel tank.

(b) Raise the transmission jack.

(c) Install the 2 fuel tank bands with the 2 pins and 2 clips.

(d) Connect the 2 fuel tank bands with the 2 bolts.

Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

6. CONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Connect the fuel tank to filler pipe hose to the fuel tank filler pipe as shown in the illustration.

HINT
* Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.
* Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

7. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY

(a) Connect the fuel tank breather tube to the fuel tank filler pipe.

HINT
Push the parts together firmly until a "click" sound is heard.

NOTICE:
* Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
* After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

(b) Attach the fuel tube clamp.

8. CONNECT NO. 2 FUEL TANK TANK BREATHER TUBE SUB-ASSEMBLY

(a) Connect the No. 2 fuel tank breather tube.

NOTICE:
* Before installing the hose, make sure that it is not damaged. Make sure that there is no foreign matter present on the connecting surfaces.
* After connecting, check if the hose and the connector are securely connected by pulling on them.

(b) Attach the 2 fuel tube clamps.

9. CONNECT FUEL TANK RETURN TUBE

(a) Connect the fuel tank return tube.

HINT
Push the parts together firmly until a "click" sound is heard.

NOTICE:
* Before installing the tube connector to the pipe, check if there is any damage or foreign matter in the connector.
* After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

(b) Attach the fuel tube clamp.

10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Connect the fuel tank main tube.

(a) Install the tank protector with the 5 bolts.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

12. INSTALL FUEL TANK CAP ASSEMBLY

13. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER

(a) Connect the fuel pump and fuel sender gauge connector.

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

(c) Install the air duct with the 2 screws.

14. INSTALL FRONT FLOOR CARPET ASSEMBLY Installation

15. INSTALL REAR AIR DUCT GUIDE Installation

16. INSTALL AIR DUCT PLUG Installation

17. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH Installation

18. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH Installation

19. INSTALL LUGGAGE COMPARTMENT NO. 1 TRIM HOOK Installation

20. INSTALL REAR FLOOR MAT REAR SUPPORT PLATE Installation

21. INSTALL REAR NO. 2 SEAT ASSEMBLY

(a) Install the rear No. 2 seat assembly Installation.

22. INSTALL REAR DOOR SCUFF PLATE RH Installation

23. INSTALL REAR DOOR SCUFF PLATE LH Installation

24. INSTALL REAR STEP COVER Installation

25. INSTALL REAR NO. 2 SEAT PROTECTOR Installation

26. INSTALL REAR NO. 1 SEAT PROTECTOR Installation

27. INSTALL REAR NO. 1 SEAT ASSEMBLY RH

(a) Install the rear No. 1 seat assembly Installation.

28. INSTALL REAR NO. 1 SEAT ASSEMBLY LH

(a) Install the rear No. 1 seat assembly Installation.

29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

30. CHECK SRS WARNING LIGHT

(a) Check the SRS warning light Diagnosis System.

31. ADD FUEL

32. INSPECT FOR FUEL LEAK Installation

33. INSPECT REAR NO. 1 SEAT ASSEMBLY RH Installation

34. INSPECT REAR NO. 1 SEAT ASSEMBLY LH Installation