Installation

1GR-FE FUEL: FUEL TANK: INSTALLATION

1. 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) Align the protrusion of the fuel suction with pump and gauge tube assembly with the groove of the fuel tank.





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(c) Install the fuel suction with pump and gauge tube assembly to the fuel tank.

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

(d) Put a new retainer on the fuel tank. While holding the fuel suction with pump and gauge tube assembly, tighten the retainer one complete turn by hand.

(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 : 09808-14020

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

(f) Install the 2 fuel tank tubes with the 2 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 cannot be pulled off.

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2. INSTALL FUEL TANK TO FILLER PIPE HOSE

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

3. INSTALL NO. 1 FUEL TANK HEAT INSULATOR

(a) Install the heat insulator with the 4 clips and nut.

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

4. INSTALL FUEL TANK INLET PIPE SUB-ASSEMBLY

(a) Install the inlet pipe with the 2 nuts.

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

5. INSTALL FUEL TANK ASSEMBLY

(a) Set the fuel tank on a engine lifter and raise the fuel tank.

(b) Attach the harness clamp and connect the fuel pump connector to the fuel tank.

NOTICE:
Be careful not to cut the wiring.

(c) Raise the engine lifter.

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

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

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

6. CONNECT NO. 1 CANISTER OUTLET HOSE

(a) Connect the canister outlet hose to the inlet pipe.

(b) Attach the hose to the No. 1 breather tube clamp.

7. CONNECT FUEL TANK TO FILLER PIPE HOSE

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

(b) Connect the fuel tank breather tube Service Precautions.

(c) Attach the filler pipe hose and breather tube to the No. 1 breather tube clamp.

8. CONNECT WIRE HARNESS

(a) Attach the harness clamp to the fuel tank.

9. CONNECT VENT LINE HOSE

(a) Connect the vent line hose and install the retainer.





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NOTICE:
* Check for damage or foreign objects on the connected part.
* After connecting the hose, check that the vent hose and the valve are securely connected by pulling on them.

10. CONNECT FUEL TANK RETURN TUBE

(a) Connect the fuel tank return tube Service Precautions.

11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Connect the fuel tank main tube Service Precautions.

12. INSTALL FUEL TANK CAP

13. 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.

14. INSPECT FOR FUEL LEAK Installation