Installation

1GR-FE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL FUEL TANK TO FILLER PIPE HOSE

(a) Hose and pipe connection is as shown in the illustration.

NOTE: The filler hose must be replaced with a new one.

2. INSTALL FUEL TANK BREATHER TUBE SUB-ASSEMBLY

(a) Push in the tube connector to the pipe until the connector makes a "click" sound and install the retainer.

NOTICE:
- Check if there is any damage or foreign objects on the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.

3. INSTALL FUEL SUCTION WITH PUMP & GAGE TUBE ASSEMBLY

(a) Install a new gasket onto the fuel tank.
(b) Set the fuel suction tube assembly to the fuel tank.

NOTE: Be careful not to bend the arm of the fuel sender gage.

(c) Fit a spline of the fuel suction tube assembly into a keyway of the fuel tank.

(d) Install a retainer.
(1) Using a new retainer, align mark on the retainer with a screw-threads starting point of the fuel tank.
(2) While holding the fuel suction tube assembly, tighten the retainer one complete turn by hand.

(e) Using a SST, tighten the retainer one more complete turn, and position the mark on the retainer into a range A of the fuel tank.
SST: 09808-14020

HINT:
- Turn the retainer two complete turns and position the mark within the range A for the installation of the retainer.
- A rib on the retainer can be fitted into a tip of the SST.

4. INSTALL FUEL TANK MAIN TUBE AND FUEL TANK RETURN TUBE

(a) Connect the fuel tank main tube with the tube joint clip.

NOTICE:
- Check that there is no scratch or foreign objects on the connecting parts.
- Check that the connector is fully inserted.
- Check that the tube joint clip is on the collar of the connector.
- After installing the tube joint clip, check if the tubes are securely connected by puling then.

5. INSTALL FUEL TANK CUSHION

(a) Install 3 new fuel tank cushions to the fuel tank.
6. INSTALL FUEL TANK ASSEMBLY
(a) Set a mission jack to the fuel tank.
(b) Install the fuel tank and 2 fuel tank bands with the 2 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
7. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY

(a) Push in the tube connector to the pipe until the connector makes a "click" sound.

NOTICE:
- Check that there is no damage or foreign objects on the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.

9. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
(a) Set a mission jack to the fuel tank protector.
(b) Install the fuel tank protector with the 6 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
10. CONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Hose and pipe connection is as shown in the illustration.
11. CHECK FOR FUEL LEAKAGE
12. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the connector.
(b) Install the 3 screws and rear floor service hole cover.
(c) Install the rear floor carpet.