Installation
2ZR-FXE FUEL: FUEL PUMP: INSTALLATION
1. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
(a) Install a new fuel suction tube set gasket onto the fuel tank.
(b) Install the fuel suction tube with pump and gauge assembly to the fuel tank.
Text in Illustration
NOTICE:
Make sure that the fuel sender gauge arm does not bend.
(c) Align the protrusions of the fuel suction tube assembly with pump and gauge with the notches of the fuel tank.
NOTICE:
Ensure that the fuel suction tube set gasket is in the correct position.
2. INSTALL FUEL PUMP GAUGE RETAINER
(a) While holding the fuel suction tube with pump and gauge assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.
Text in Illustration
NOTICE:
Check that the contact surface of the fuel tank retainer is not scratched or damaged, and prevent the entry of foreign matter.
(b) Temporarily install the SST plate and claws to the fuel pump gauge retainer.
Text in Illustration
SST : 09808-14030
09808-01030
09808-01040
09808-01050
HINT
* Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.
* Engage the SST claws securely with the fuel pump gauge retainer holes to secure SST.
* Make sure that only 2 claws are used with SST.
(c) While pressing the claws of SST to the fuel pump gauge retainer ribs securely, tighten the bolts.
HINT
Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST).
(d) Install the SST handle.
(e) Using SST, align the marks on the fuel tank and fuel pump gauge retainer.
Text in Illustration
SST : 09808-14030
09808-01010
09808-01020
09808-01030
09808-01040
09808-01050
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.
* Tighten the retainer by turning it clockwise while holding SST down.
* Make sure to rotate the SST handle horizontally. If the SST handle is rotated at an angle, SST may come off.
* Do not spin SST too fast or use an impact wrench as this may result in damage to components.
* If SST comes off of the retainer, loosen the SST bolts and reinstall SST.
3. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY
(a) Push in the fuel tank vent hose connector to the fuel suction tube assembly and push the retainer so that the claws engage.
Text in Illustration
NOTICE:
* Check that there are no scratches or foreign matter around the connected parts of the fuel tank vent hose connector and fuel suction tube assembly 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 tank vent hose connector.
(b) Install the No. 2 fuel tank protector with the 3 nuts.
Torque : 4.5 Nm (46 kgf-cm, 40 in-lbf)
4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Push the fuel tube joint onto the plug of the fuel suction plate, then install the tube joint clip.
Text in Illustration
NOTICE:
* Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work.
* Check that the fuel tube joint is securely inserted to the end.
* Check that the tube joint clip is on the collar of the fuel tube joint.
* After installing the tube joint clip, check that the fuel tank main tube cannot be pushed out.
(b) Connect the fuel pump connector.
5. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
6. INSPECT FOR FUEL LEAK Fuel System
7. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Install the rear floor service hole cover with new butyl tape.
Text in Illustration
(b) Install the rear floor carpet.
(c) Install the clip and engage the floor carpet hook.
8. INSTALL REAR NO. 1 FLOOR BOARD Installation
9. INSTALL FRONT DECK FLOOR BOX Installation
10. INSTALL TONNEAU COVER ASSEMBLY (w/ Tonneau Cover) Installation
11. INSTALL DECK FLOOR BOX RH Installation
12. INSTALL REAR DECK FLOOR BOX Installation
13. INSTALL NO. 1 DECK BOARD Installation
14. INSTALL NO. 2 DECK BOARD Installation
15. INSTALL DECK BOARD ASSEMBLY Installation
16. INSTALL REAR NO. 1 SEAT ASSEMBLY LH
Installation
17. INSTALL REAR NO. 1 SEAT ASSEMBLY RH
Installation