Filler neck installation (RZ4E-TC)

1. Filler neck installation

1. Filler neck hose installation

1) Connect the fuel filler hose to the fuel tank fuel filler pipe.

Note

  • Align the mark so that it faces upward, and insert the hose until it reaches the spool.

Tightening torque: 2.0 N・m { 0.2 kgf・m / 18 lb・in }

2) Connect the breather hose to the fuel tank breather pipe.

Note

  • Align the mark so that it faces upward, and insert the hose until it reaches the spool.

Except flat deck specifications

Legend

  1. Fuel tank
  2. Fuel filler hose
  3. Breather hose
  4. Clamp

Flat deck specifications

  1. Fuel tank
  2. Fuel filler hose
  3. Breather hose
  4. Clamp

3) Referring to the following, install the fuel tank to the vehicle.

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel tank installation".

2. Filler neck pipe installation (Except flat deck specifications)

1) Install the filler neck to the vehicle.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

Caution

  • Firmly install to the bracket guide hole.

2) Install the recess to the rear body.

Caution

  • Do not reuse the recess.

3) Connect the breather hose to the filler neck pipe.

Note

  • Insert the hose until it reaches the filler neck pipe side bracket end.

Caution

  • Install to the original position by aligning the marks applied before removing.

4) Connect the fuel filler hose to the filler neck pipe.

Note

  • Insert the hose until it reaches the filler neck pipe side bracket end.

Caution

  • Install to the original position by aligning the marks applied before removing.

Tightening torque: 3.0 N・m { 0.3 kgf・m / 27 lb・in }

Legend

  1. Breather hose
  2. Fuel filler hose
  3. Rear axle breather hose (2WD (High ride suspension specifications) and 4WD)

5) Referring to the following, install the band clip to the fuel filler hose and breather hose.

Note

  • Secure it at the breather hose straight section.
  • Install so that the band clip end faces the center of the hose.

Legend

  1. Breather hose
  2. Fuel filler hose
  3. Straight section

Dimensions

a: 169 mm { 6.65 in }

b: 5 to 10 mm { 0.20 to 0.39 in }

6) Referring to the following, install the band clip to the rear axle breather hose. (2WD (High ride suspension specifications) and 4WD)

Legend

  1. Rear axle breather hose (2WD (High ride suspension specifications) and 4WD)
  2. Fuel filler hose
  3. Band clip

Caution

  • Align the rear axle breather hose end with the fuel filler hose marking to secure.

Legend

  1. Fuel filler hose
  2. Marking
  3. Rear axle breather hose (2WD (High ride suspension specifications) and 4WD)

Caution

  • Align the band clip with the center of the filler hose and rear axle breather hose to install.
  • Cut the band clip end to fit the dimension.

Dimensions

a: 10 mm { 0.39 in }

Caution

  • After securing with the band clip, place the rear axle breather hose on the filler hose clip.
  • Do not let the rear axle breather hose interfere with other components.

Legend

  1. Rear axle breather hose (2WD (High ride suspension specifications) and 4WD)
  2. Filler hose clip

3. Filler neck pipe installation (Flat deck specifications)

1) Install the filler neck pipe to the vehicle.

Tightening torque: 5.9 N・m { 0.6 kgf・m / 52 lb・in }

2) Connect the breather hose to the filler neck pipe.

Caution

  • Install to the original position by aligning the marks applied before removing.

3) Connect the fuel filler hose to the filler neck pipe.

Caution

  • Install to the original position by aligning the marks applied before removing.

Tightening torque: 3.0 N・m { 0.3 kgf・m / 27 lb・in }

Legend

  1. Breather hose
  2. Fuel filler hose

2. Rear mudguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors rear mudguard installation".

3. Fuel filler cap installation

Refer to "1.Engine 1C.Fuel System(RZ4E-TC) fuel filler cap installation".

4. Preliminary and post procedures

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.

5. Fuel air bleed

1) Press the priming pump until it becomes hard.

Caution

  • Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.

Legend

  1. Priming pump
  2. Fuel filter with sedimenter

6. Fuel vehicle inspection

1) Start the engine.

2) Inspect the fuel system for loose connections.

Note

  • Inspect for fuel leakage.
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