Installation

2ZR-FXE FUEL: FUEL TANK: INSTALLATION

1. INSTALL FUEL TANK TO FILLER PIPE HOSE

(a) Align the alignment marks and install the fuel tank to filler pipe hose to the fuel tank.





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(b) Install the hose clamp within the range shown in the illustration.

2. INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Connect the No. 1 fuel tube clamp to the fuel tank breather tube.

(b) Install the fuel tank vent hose sub-assembly to the No. 1 fuel tube clamp.

3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Install the fuel tank main tube sub-assembly, and engage the 2 claws.

4. INSTALL NO. 1 FUEL TANK CUSHION

(a) Install 4 new No. 1 fuel tank cushions as shown in the illustration.





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5. INSTALL NO. 2 FUEL TANK CUSHION

(a) Install 2 new No. 2 fuel tank cushions as shown in the illustration.

6. INSTALL FUEL TANK ASSEMBLY

(a) Support the fuel tank using an engine lifter.

(b) Raise the engine lifter, then install the fuel tank to the vehicle.

NOTICE:
* Do not drop the fuel tank.
* When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

(c) Tighten the 4 set bolts of the 2 fuel tank bands.

Torque : 39 Nm (400 kgf-cm, 29 ft-lbf)

7. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Align the quick connector with the pipe, connect the quick connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer.





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NOTICE:
* Check that there are no scratches or foreign matter around the connected part of the fuel tank main tube connector and pipe before starting this step.
* After connecting the fuel tank main tube connector, check that the fuel tank main tube connector is securely connected by pulling on the fuel tube connector.

8. CONNECT FUEL TANK BREATHER TUBE

(a) Align the quick connector with the pipe, connect the quick connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer.





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NOTICE:
* Check that there are no scratches or foreign matter around the connected part of the fuel tank breather tube connector and pipe before starting this step.
* After connecting the fuel tank breather tube connector, check that the fuel tank breather tube connector is securely connected by pulling on the fuel tank breather tube connector.

(b) Connect the fuel tank vent hose sub-assembly and fuel tank breather tube to the No. 1 fuel tube clamp.

9. CONNECT FUEL TANK TO FILLER PIPE HOSE

(a) Connect the fuel tank to filler pipe hose to the fuel tank, then fit it with the clamp as shown in the illustration.





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10. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY

(a) Push in the fuel tank vent hose connector to the charcoal canister and push up the retainer so that the claws engage.





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NOTICE:
* Check that there are no scratches or foreign matter around the connected part of the fuel tank vent hose connector and charcoal canister 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 and the charcoal canister.

11. INSTALL NO. 1 FUEL TANK PROTECTOR

(a) Install the No. 1 fuel tank protector with the 4 clips.

12. INSTALL REAR SUSPENSION BRACE SUB-ASSEMBLY Installation

13. INSTALL FRONT EXHAUST PIPE ASSEMBLY

Installation

14. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Installation

15. ADD FUEL

16. INSPECT FOR EXHAUST GAS LEAK