Installation
2GR-FE FUEL: FUEL TANK: INSTALLATION
1. INSTALL FUEL TANK CUSHION SET
(a) Install the fuel tank cushion sets and No. 5 fuel tank cushions.
2. INSTALL FUEL TANK SIDE PLATE
(a) Install the fuel tank side plate and the fuel tank bracket with the bolt and nut.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
3. INSTALL TANK SUCTION TUBE SUPPORT
(a) Install a new tank suction tube support as shown in the illustration.
4. INSTALL FUEL TANK OVER FILL CHECK VALVE ASSEMBLY
(a) Install a new tank suction tube support and new gasket as shown in the illustration.
(b) Attach the fuel tank over fill check valve assembly to the fuel tank.
(c) Align the keyway of the fuel suction tube support with the key of the fuel tank over fill check valve assembly.
(d) Align the triangle mark on a new fuel pump gauge retainer with the "S" mark, and attach the fuel pump gauge retainer.
(e) Using a 6 mm socket hexagon wrench, install SST to the fuel pump gauge retainer.
SST : 09808-14020
09808-01410
09808-01420
09808-01430
HINT
* Engage the SST claws securely with the fuel pump gauge retainer ribs to secure SST.
* Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST).
(f) Rotate the fuel pump gauge retainer by hand, then tighten it one complete turn and another half turn using SST. The triangle mark on the fuel pump gauge retainer must be positioned between the "MIN" and "MAX" marks on the fuel tank.
SST : 09808-14020
09808-01410
09808-01420
09808-01430
NOTICE:
* Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
* Fully tighten the retainer by turning it clockwise while holding SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank.
HINT
The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.
5. INSTALL FUEL TANK VENT HOSE
(a) Connect the No. 1 evaporation vent tube.
(1) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a click sound. If the connection is too tight, apply a small amount of fresh engine oil to the tip of the pipe.
NOTICE:
* Check for damage or foreign objects on the parts that are to be connected.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(b) Connect the fuel tank vent hose.
(1) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a click sound. If the connection is too tight, apply a small amount of fresh engine oil to the tip of the pipe.
NOTICE:
* Check for damage or foreign objects on the parts that are to be connected.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(2) Install the fuel tank vent hose, and engage the claw.
6. INSTALL FUEL TANK TO FILLER PIPE HOSE
(a) Install the fuel tank to filler pipe hose with the hose clamp.
7. INSTALL FUEL PUMP TUBE SUB-ASSEMBLY
(a) Install the fuel pump tube, and engage the 2 claws.
8. INSTALL NO. 1 FUEL TANK CUSHION
(a) Apply new butyl tape to the positions of the No. 1 fuel tank cushion as shown in the illustration.
Length:
(b) Install the No. 1 fuel tank cushion.
9. INSTALL REAR FUEL TANK SIDE PLATE
(a) Install the rear fuel tank side plate.
10. INSTALL FUEL TANK ASSEMBLY
(a) Set the fuel tank onto a transmission jack.
(b) Operating the transmission jack, install the fuel tank.
(c) Tighten the 2 nuts.
Torque : 20 Nm (200 kgf-cm, 14 ft-lbf)
(d) Install the 2 fuel tank bands with the 4 bolts.
Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)
(e) Align the matchmarks and install the fuel tank to filler pipe hose to the fuel tank.
(f) Install the hose clamp within the range shown in the illustration.
HINT
* A = 45°
* B = 120°
(g) Connect the fuel tank vent hose.
(1) Align the quick connector with the pipe, then push in the quick connector until the retainer makes a click sound to connect the charcoal canister fuel hose to the charcoal canister assembly.
NOTICE:
* Check that there are no scratches or foreign objects around the connected part of the quick connector and pipe before this work.
* After connecting the charcoal canister fuel hose, check if the quick connector and the pipe are securely connected by pulling on them.
(h) Connect the No. 3 fuel tank breather tube.
(1) Push the quick connector to the pipe until it makes a click sound.
NOTICE:
* Check if there is any damage or foreign objects on the connected part.
* After connecting, check if the quick connector and the pipe are securely connected by pulling on them.
(i) Connect the fuel pump tube.
(1) Push the quick connector and push in the retainer to lock the claws.
NOTICE:
* Check if there is any damage or foreign objects on the connected part.
* After connecting, check if the quick connector and the pipe are securely connected by pulling on them.
11. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
(a) Install the No. 1 fuel tank protector sub-assembly with the 7 nuts.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(b) Install 3 new clips (A).
12. TEMPORARILY INSTALL REAR SUSPENSION MEMBER (for 4WD) Installation
13. FULLY TIGHTEN REAR SUSPENSION MEMBER (for 4WD) Installation
14. INSTALL REAR DRIVE SHAFT SNAP RING LH (for 4WD)
15. INSTALL REAR DRIVE SHAFT ASSEMBLY LH (for 4WD)
16. INSTALL REAR DRIVE SHAFT SNAP RING RH (for 4WD) Installation
17. INSTALL REAR DRIVE SHAFT ASSEMBLY RH (for 4WD) Installation
18. INSTALL REAR DIFFERENTIAL DRAIN PLUG (for 4WD) Installation
19. ADD DIFFERENTIAL OIL (for 4WD) Installation
20. INSPECT DIFFERENTIAL OIL (for 4WD)
21. INSTALL REAR DIFFERENTIAL FILLER PLUG (for 4WD) Installation
22. TEMPORARILY INSTALL REAR NO. 1 SUSPENSION ARM ASSEMBLY RH (for 4WD) Installation
23. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (for 4WD) Installation
24. TEMPORARILY INSTALL REAR NO. 2 SUSPENSION ARM ASSEMBLY RH (for 4WD) Installation
25. INSTALL REAR AXLE CARRIER SUB-ASSEMBLY LH (for 4WD) Installation
26. INSTALL REAR AXLE CARRIER SUB-ASSEMBLY RH (for 4WD) Installation
27. TEMPORARILY INSTALL REAR STRUT ROD ASSEMBLY LH (for 4WD) Installation
28. TEMPORARILY INSTALL REAR STRUT ROD ASSEMBLY RH (for 4WD) Installation
29. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY LH (for 4WD) Installation
30. INSTALL REAR AXLE HUB AND BEARING ASSEMBLY RH (for 4WD) Installation
31. INSTALL REAR DISC (for 4WD LH Side)
32. INSTALL REAR DISC (for 4WD RH Side)
33. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH (for 4WD) Replacement
34. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH (for 4WD) Installation
35. TEMPORARILY INSTALL REAR AXLE SHAFT NUT LH (for 4WD) Installation
36. TEMPORARILY INSTALL REAR AXLE SHAFT NUT RH (for 4WD) Installation
37. INSTALL REAR SPEED SENSOR LH (for 4WD) Installation
38. INSTALL REAR SPEED SENSOR RH (for 4WD) Installation
39. STABILIZE SUSPENSION (for 4WD) Installation
40. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH (for 4WD) Installation
41. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH (for 4WD) Installation
42. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH (for 4WD) Installation
43. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH (for 4WD) Installation
44. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY LH (for 4WD) Installation
45. FULLY TIGHTEN REAR STRUT ROD ASSEMBLY RH (for 4WD) Installation
46. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY (for 4WD) Installation
47. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY (for 4WD) Installation
48. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY LH (for 4WD) Replacement
49. SEPARATE REAR DISC BRAKE CALIPER ASSEMBLY RH (for 4WD) Installation
50. REMOVE REAR DISC (for 4WD LH Side)
51. REMOVE REAR DISC (for 4WD RH Side)
52. INSPECT REAR AXLE HUB BEARING LOOSENESS (for 4WD LH Side) Rear Axle Hub
53. INSPECT REAR AXLE HUB BEARING LOOSENESS (for 4WD RH Side) Installation
54. INSPECT REAR AXLE HUB RUNOUT (for 4WD LH Side) Rear Axle Hub
55. INSPECT REAR AXLE HUB RUNOUT (for 4WD RH Side) Installation
56. INSTALL REAR DISC (for 4WD LH Side)
57. INSTALL REAR DISC (for 4WD RH Side)
58. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH (for 4WD) Replacement
59. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH (for 4WD) Installation
60. INSTALL REAR AXLE SHAFT NUT LH (for 4WD) Installation
61. INSTALL REAR AXLE SHAFT NUT RH (for 4WD) Installation
62. INSTALL REAR WHEELS (for 4WD)
63. INSTALL NO. 3 FRONT FLOOR HEAT INSULATOR Installation
64. INSTALL NO. 4 EXHAUST PIPE SUPPORT BRACKET
(a) Install the No. 4 exhaust pipe support bracket with the 2 bolts.
Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)
65. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation
66. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation
67. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) Installation
68. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) Installation
69. INSTALL FRONT CENTER FLOOR COVER Installation
70. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
Installation
71. INSPECT EXHAUST GAS LEAK Installation
72. INSPECT AND ADJUST TRANSFER OIL (for 4WD) Testing and Inspection
73. INSPECT REAR WHEEL ALIGNMENT (for 4WD) Installation
74. CHECK FOR SPEED SENSOR SIGNAL (for 4WD) Installation