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Home >> Lexus >> 2008 >> GS 350 RWD V6-3.5L (2GR-FSE) >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Tank >> Service and Repair >> Installation

Installation









2GR-FSE FUEL: FUEL TANK: INSTALLATION





1. INSTALL NO. 1 FUEL TANK PROTECTOR
(a) Install the tank protector with the 2 nuts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)






2. INSTALL FUEL TANK CUSHION
(a) Install the tank cushions and tank brackets.
3. INSTALL FUEL RETURN TUBE






4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
(a) Attach the fuel tank main tube to the clamps, and install it.
5. INSTALL FUEL TANK SUB-ASSEMBLY
(a) Set the fuel tank on a mission jack, and raise the fuel tank.
(b) Install the 2 fuel tank bands with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
(c) Install the 2 nuts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)






6. CONNECT FUEL EMISSION HOSE
(a) Connect the 2 emission hoses.
(b) Connect the fuel tank bracket hose.






7. CONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Tighten the clamp and connect the fuel tank to filler pipe hose.
8. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY






(a) Connect the fuel tank main tube LH.
HINT:
Push the parts together firmly until a "click" sound is heard.
NOTICE:

- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.






(b) Connect the fuel tank main tube RH.
HINT:
Push the parts together firmly until a "click" sound is heard.
NOTICE:

- Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
- After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.






9. CONNECT FUEL RETURN TUBE
(a) Connect the fuel return tube and install the retainer.






10. CONNECT PARKING BRAKE CABLE ASSEMBLY
(a) Connect the 4 clamps.
(b) Connect the 2 parking brake cables with the 4 bolts.
Bolt A - Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
Bolt B - Torque: 19 Nm (193 kgf-cm, 14 ft-lbf)






11. INSTALL REAR FLOOR SIDE MEMBER COVER LH
(a) Install the member cover with the 2 bolts.






12. INSTALL REAR FLOOR SIDE MEMBER COVER RH
(a) Install the member cover with the 2 bolts.






13. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR
(a) Install the differential support protector with the 2 nuts.
14. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR
(a) Install the differential support protector with the 2 nuts.






15. INSTALL NO. 2 FUEL TANK PROTECTOR
(a) Install the tank protector with the 4 nuts.
Torque: 5.0 Nm (51 kgf-cm, 48 in-lbf)
16. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 4WD) Installation

17. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 2WD) Installation

18. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 4WD) Installation

19. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 2WD) Installation

20. INSTALL AIR GUIDE PLATE OUTSIDE RH Installation







21. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
(a) Install the heat insulator with the 4 nuts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)






22. INSTALL FRONT FLOOR COVER CENTER RH
(a) Attach the 2 clips, and install the floor cover center with the 3 nuts.
23. INSTALL EXHAUST PIPE ASSEMBLY
(a) Install the exhaust pipe Installation.
24. INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY






(a) Install the fuel sender gauge.
(1) Set the fuel sender gauge to the fuel vent tube. Then slide the sender gauge downward to install it.
(2) Connect the fuel sender gauge connector.
(b) Apply a light coat of gasoline to a new gasket, and set it to the fuel tank.






(c) Set the fuel return vent tube sub-assembly to the fuel tank as shown in the illustration.
NOTICE:

- Be careful not to bend the arm of the fuel sender gauge.


(d) Align the protrusion of the fuel return vent tube sub-assembly and the cutout of the fuel tank.






(e) While holding the fuel tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Then install the fuel pump gauge retainer to the fuel tank.






(f) Using a 6 mm socket, set SST to the fuel pump gauge retainer.
SST: 09808-14020
HINT:
Fit the tips of SST on the ribs of the retainer.
NOTICE:
Use SST. Do not any other tools such as a screwdriver.





(g) Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the starting mark on the retainer is within the indicated range in the illustration.






(h) Connect the fuel return tube.
(1) Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip.
NOTICE:
- Check that there are no scratches or foreign matter around the connected parts of the fuel tube joint and plug before performing this work.
- Check that the fuel tube joint is securely inserted.
- 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 tube cannot be pulled out.





25. INSTALL REAR FLOOR SERVICE HOLE COVER
(a) Connect the fuel sender gauge connector.
(b) Install the service hole cover with new butyl tape.
26. INSTALL FUEL SUCTION WITH PUMP AND GAUGE ASSEMBLY Installation

27. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER Installation

28. INSTALL ROOM NO. 3 PARTITION PAD Installation

29. INSTALL REAR SEAT CUSHION ASSEMBLY Installation

30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
31. INSPECT FOR FUEL LEAK Testing and Inspection

32. INSPECT FOR EXHAUST GAS LEAK Installation

33. PERFORM INITIALIZATION
(a) Perform initialization Repair Instruction - Initialization.
NOTICE:
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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