Installation

2GR-FE FUEL: FUEL TANK: INSTALLATION

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, 22ft-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 the new fuel pump gauge retainer with the "S" mark, and attach the fuel pump gauge retainer.

(e) 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 other tools in this operation. Damage to the fuel pump gauge retainer and the fuel tank may result.
HINT: A rib on the fuel pump gauge retainer can be fitted into a tip of the 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.
- 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.

(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 fasten the 2 claws.
8. INSTALL FUEL TANK ASSEMBLY
(a) Set up the fuel tank to the transmission jack.
(b) Operating the transmission jack, install the fuel tank.
(c) Tighten the 2 nuts.

Torque: 20 Nm (200 kgf-cm, 14ft-lbf)
(d) Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29ft-lbf)

(e) Connect the fuel tank to filler pipe hose.

(f) Connect the No. 3 fuel tank breather tube.
(1) Push the quick connector to the pipe until it makes a "click" sound.
- 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.

(g) Connect the fuel tank vent hose.

(h) Connect the fuel pump tube.
(1) Push the quick connector and push up the retainer to lock the claws.
- 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.

9. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

(a) Install the No. 1 fuel tank protector with the 6 nuts.
Torque: 5.5 Nm (56 kgf-cm, 49in-lbf)
(b) Install 3 new clips. (A)
10. INSTALL NO. 1 FUEL TANK PROTECTOR

(a) Install the No. 1 fuel tank protector with the 4 nuts.
Torque: 5.5 Nm (56 kgf-cm, 49in-lbf)
11. INSTALL NO. 1 FUEL TUBE PROTECTOR

(a) Install the No. 1 fuel tube protector with the 2 clips and claw.
12. INSTALL NO. 4 EXHAUST PIPE SUPPORT BRACKET (for 4WD)

(a) Install the No. 4 exhaust pipe support bracket with the 2 bolts.
Torque: 22 Nm (224 kgf-cm, 16ft-lbf)
13. INSTALL NO. 3 FRONT FLOOR HEAT INSULATOR Installation
14. INSTALL EXHAUST CENTER PIPE ASSEMBLY
HINT:
Installation.

15. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)
16. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
17. INSTALL NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover)
18. ADD FUEL
19. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE Installation
20. INSPECT FOR FUEL LEAK
HINT:
Installation.

21. INSPECT FOR EXHAUST GAS LEAK
22. INSTALL REAR FLOOR SERVICE HOLE COVER Installation
23. INSTALL REAR SEAT SIDE COVER LH
24. INSTALL DECK SIDE TRIM COVER LH
25. INSTALL REAR DOOR SCUFF PLATE LH
26. INSTALL REAR SEAT ASSEMBLY LH
HINT:
Installation.

27. INSTALL REAR SEAT ASSEMBLY RH
HINT:
Installation.

28. INSTALL DECK BOARD SUB-ASSEMBLY