Installation

2ZR-FE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL FUEL TANK CUSHION





(a) Install new fuel tank cushions onto the fuel tank.
2. INSTALL FUEL TANK VENT HOSE





(a) Install the fuel tank vent hose onto the fuel tube clamp.
3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Install the fuel tank main tube onto the fuel tank.
4. INSTALL FUEL TANK ASSEMBLY
(a) Set the fuel tank on a transmission jack.





(b) Operate the transmission jack, then install the fuel tank into the vehicle.
(c) Install the 2 No. 1 fuel tank bands with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
5. INSTALL FUEL TANK FILLER PIPE SUB-ASSEMBLY





(a) Connect the fuel tank filler pipe to the fuel tank.
NOTE: Make sure that the hose clamp is facing the correct direction when installing.





(b) Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Connect the fuel tank main tube.
(1) Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
NOTICE:
- Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.

7. CONNECT BREATHER TUBE FUEL HOSE





(a) Connect the breather tube fuel hose.





(b) Connect the breather tube fuel hose.
(1) Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank breather tube, check that the fuel pump tube is securely connected by pulling on the fuel tube connector and pipe.
(2) Install the checker onto the pipe.
8. CONNECT FUEL TANK VENT HOSE





(a) Connect the fuel tank vent hose.
(1) Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
(2) Slide the retainer of the fuel tube connector to lock the claws as shown in the illustration.
NOTICE:
- Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tube connector.

9. INSTALL CHARCOAL CANISTER ASSEMBLY Removal
10. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY





(a) Install the fuel tank protector sub-assembly with the 4 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
11. CONNECT PARKING BRAKE CABLE





(a) Install the parking brake cables with the 4 bolts.
12. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
13. ADD FUEL
14. INSTALL FUEL SENDER GAUGE SUB-ASSEMBLY Installation
15. INSTALL FUEL SUCTION TUBE ASSEMBLY
(a) Install the fuel suction tube assembly to the fuel tank assembly Reassembly.
16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
17. INSPECT FOR FUEL LEAK Testing and Inspection
18. INSPECT FOR EXHAUST GAS LEAK