Installation

1NR-FE FUEL: FUEL TANK: INSTALLATION

1. INSTALL NO. 1 EVAPORATION VENT TUBE CLAMP

(a) Engage the claw and install the No. 1 evaporation tube clamp.

2. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY

(a) Insert the fuel tank vent tube from the sender gauge side, in the direction indicated by the arrows on the fuel tank, run the tube along the bottom edge of the fuel tank, and then pull it out on the fuel pump side.





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NOTICE:
Do not run the fuel tank vent tube on the other side of the recession shown in the illustration.

3. INSTALL FUEL TANK SUCTION TUBE GASKET

(a) Install a new gasket to the fuel tank.

4. INSTALL FUEL SUCTION TUBE ASSEMBLY

(a) Line up the pipe and connector and push them together until a "click" sound is heard.





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NOTICE:
* Check that there are no scratches or foreign objects on the pipe and connector before connecting them.
* After connecting the pipe and connector, check that the pipe and connector are securely connected by pulling on them.

(b) Install the fuel suction tube to the fuel tank.

5. INSTALL FUEL PUMP GAUGE RETAINER

(a) Align the protrusion of the fuel suction tube with the cutouts of the fuel tank.





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NOTICE:
Ensure that the fuel suction tube gasket is in the correct position.

(b) While holding the fuel suction tube by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

NOTICE:
Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.

(c) Set the plate and claws of SST onto the fuel pump gauge retainer and temporarily tighten the bolts.

SST : 09808-14030

09808-01030

09808-01040

09808-01050

(d) While firmly pressing the claws of SST against the ribs of the retainer, fully tighten each bolt.

(e) Set SST handle in place.

SST : 09808-14030

09808-01010

09808-01020

(f) Using SST, align the marks on the fuel tank and fuel pump gauge retainer.





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6. INSTALL FUEL TANK SUCTION TUBE GASKET

(a) Install a new gasket to the fuel tank.

7. INSTALL FUEL TANK VENT TUBE ASSEMBLY

(a) Engage the 2 claws and connect the fuel tank vent tube sub-assembly to the fuel tank vent tube assembly.

(b) Rotate the fuel tank vent tube in the direction shown by the arrows, insert the sender gauge in the direction of the fuel tank gauge shown by the arrows, and then install the fuel tank vent tube assembly into the fuel tank.





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NOTICE:
Do not bend the sender gauge arm.

8. INSTALL FUEL PUMP GAUGE RETAINER

(a) Align the protrusion of the fuel tank vent tube assembly with the cutouts of the fuel tank.





Text in Illustration





NOTICE:
Ensure that the fuel suction tube gasket is in the correct position.

(b) While holding the fuel tank vent tube assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

NOTICE:
Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.

(c) Set the plate and claws of SST onto the fuel pump gauge retainer and temporarily tighten the bolts.

SST : 09808-14030

09808-01030

09808-01040

09808-01050

(d) While firmly pressing the claws of SST against the ribs of the retainer, fully tighten each bolt.

(e) Set SST handle in place.

SST : 09808-14030

09808-01010

09808-01020

(f) Using SST, align the marks on the fuel tank and fuel pump gauge retainer.





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(g) Connect the fuel tank breather tube to the fuel tank vent tube assembly and lock it by pushing in the retainer.





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NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the fuel tank breather tube is inserted securely.
* After installing the retainer, check that the fuel tank breather tube is securely connected by pulling on it.

9. INSTALL FUEL TANK VENT HOSE





(a) Connect the fuel tank vent hose to the fuel tank vent tube assembly and lock it by pushing in the retainer.

Text in Illustration





NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the fuel tank vent hose is inserted securely.
* After installing the retainer, check that the fuel tank vent hose is securely connected by pulling on it.

(b) Engage the fuel tank vent hose.

10. INSTALL NO. 2 FUEL EVAPORATION TUBE SUB-ASSEMBLY

(a) Connect the No. 2 fuel evaporation tube to the fuel tank vent tube assembly and lock it by pushing in the retainer.





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NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the No. 2 fuel evaporation tube is inserted securely.
* After installing the retainer, check that the No. 2 fuel evaporation tube is securely connected by pulling on it.

(b) Engage the clamp and install the No. 2 fuel evaporation tube.

11. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

(a) Connect the No. 1 fuel evaporation tube to the fuel suction tube assembly and fuel tank vent tube assembly and lock them by pushing in the retainers.





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NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the No. 1 fuel evaporation tube is inserted securely.
* After installing the retainer, check that the No. 1 fuel evaporation tube is securely connected by pulling on it.

(b) Engage the clamp and install the No. 1 fuel evaporation tube.

12. INSTALL FUEL TANK WIRE

(a) Install the fuel hose clamp to the fuel tank wire.

(b) Connect the fuel tank wire connectors to the fuel suction tube and fuel tank vent tube assembly.

(c) Engage the 7 clamps and install the fuel tank wire.

NOTICE:
After connecting the fuel tank wire connector, check that the fuel tank wire is inserted securely.

13. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Insert the fuel tank main tube into the fuel suction tube plug and lock it with the tube joint clip.





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NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the fuel tank main tube is inserted securely.
* Check that the tube joint clip is on the collar of the fuel tank main tube.
* After installing the tube joint clip, check that the fuel tank main tube is securely connected by pulling on it.

(b) Engage the clamp and install the fuel tank main tube.

14. INSTALL FUEL TANK CUSHION

(a) Install the No. 1 fuel tank cushions, No. 2 fuel tank cushions, No. 3 fuel tank cushions and the No. 4 fuel tank cushion at the locations indicated in the illustration.





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15. INSTALL NO. 1 FUEL TANK PROTECTOR

(a) Install the fuel tank protector with the 3 nuts.

Torque : 4.5 Nm (46 kgf-cm, 40 in-lbf)

16. INSTALL FUEL TANK ASSEMBLY

(a) Clean and degrease the bolt holes.

(b) Set the fuel tank and 2 fuel tank bands on the engine lifter.

(c) Slowly raise the engine lifter and install the fuel tank onto the vehicle.

NOTICE:
Make sure that the fuel tank does not fall.

(d) Tighten the 4 bolts in the sequence shown in the illustration, and secure the 2 fuel tank bands and the fuel tank.





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

17. INSTALL FUEL TANK FILLER PIPE PROTECTOR

(a) Engage the claw and install the fuel tank filler pipe protector.

18. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY

(a) Connect the fuel tank breather tube and lock it by pushing in the retainer.





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NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the breather tube is inserted securely.
* After installing the retainer, check that the breather tube is securely connected by pulling on it.

HINT
The quick connector cannot be locked when the tube is not inserted securely.

19. CONNECT FUEL TANK VENT HOSE





(a) Connect the fuel tank vent hose and lock it by pushing in the retainer.





NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the breather tube is inserted securely.
* After installing the retainer, check that the breather tube is securely connected by pulling on it.

20. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Line up the pipe and connector and push them together until a "click" sound is heard.





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(b) Push the checker in to lock it.

NOTICE:
* Check that there are no scratches or foreign objects on the connecting part.
* Check that the fuel tank main tube is inserted securely.
* After installing the checker, check that the fuel tank main tube is securely connected by pulling on it.

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

(a) Engage the claw and install the No. 1 fuel tank protector with the 2 clips and 4 nuts.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

22. CONNECT FUEL TANK WIRE

(a) Pull the fuel tank wire through the floor, install the grommet in the floor, and connect the fuel tank wire connector.

23. ADD FUEL

(a) Open the fuel tank cap to add fuel.

24. INSPECT FOR FUEL LEAK Fuel System