1ZR-FE FUEL  FUEL TANK  INSTALLATION  


PROCEDURE

Hide 77651A 1.INSTALL NO. 1 FUEL TANK CUSHION

a.

Install 7 new No. 1 fuel tank cushions to the fuel tank sub-assembly.


Hide 77011 2.INSTALL LOWER FUEL TANK FILLER PIPE SUB-ASSEMBLY

a.

Install a new lower fuel tank filler pipe gasket and the lower fuel tank filler pipe sub-assembly to the fuel tank sub-assembly with the 5 bolts.

Torque:
3.5 N*m (36 kgf*cm, 31 in.*lbf)


Hide 77249 3.INSTALL FUEL EMISSION HOSE

a.

Engage the 2 claws to install the fuel emission hose to the fuel tank sub-assembly.


Hide 4.INSTALL BREATHER TUBE FUEL HOSE

a.
A310757C01
0.792,2.552 1.104,2.708 0.313,0.156 10 false *a 1.708,2.792 2.323,2.99 0.615,0.198 10 false *b
*a Upper
*b 180°


Install the breather tube fuel hose to the fuel tank sub-assembly and tighten the clamp to secure it.

HINT:

Make sure the clamp bolt is within the area shown in the illustration.



Hide 77284 5.INSTALL FUEL TUBE CLAMP

a.

Engage the 2 claws to install the fuel tube clamp to the fuel tank sub-assembly.


Hide 77158A 6.INSTALL TANK SUCTION TUBE SUPPORT

a.

Engage the 2 claws to install the 2 tank suction tube supports to the fuel tank sub-assembly.


Hide 75259A 7.INSTALL FUEL HOSE

a.

Engage the 3 clamps to install the fuel hose to the 2 tank suction tube supports and fuel tube clamp.


Hide 77209F 8.INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

a.

Engage the 3 clamps to install the fuel tank main tube sub-assembly to the 2 tank suction tube supports and fuel tube clamp.


Hide 77001A 9.INSTALL FUEL TANK SUB-ASSEMBLY

a.

Set the fuel tank sub-assembly on an engine lifter.

HINT:

Using height adjustment attachments and plate lift attachments, place the fuel tank sub-assembly horizontally.



b.

Using the engine lifter, slowly raise the fuel tank sub-assembly, and then install the fuel tank sub-assembly with the fuel tank band sub-assembly LH and fuel tank band sub-assembly RH with the 4 bolts.

Torque:
39.2 N*m (400 kgf*cm, 29 ft.*lbf)

NOTICE:
·

Do not drop the fuel tank sub-assembly.

·

When installing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.




Hide 77641A 10.INSTALL NO. 1 FUEL TANK PROTECTOR

a.

Using an air riveter or a hand riveter with a nose piece, attach the No. 1 fuel tank protector to the fuel tank sub-assembly with 4 new rivets.

A321286C01
0.594,2.146 2.802,3.698 2.208,1.552 3.604,0.073 6.219,0.99 2.615,0.917 3.604,1.031 6.219,3.719 2.615,2.688 0.792,1.51 1.5,1.51 false 1.542,3.365 1.542,2.896 false 1.99,2.656 2.177,2.344 2.177,2.344 2.292,2.344 false 3.948,3.417 3.948,1.323 3.948,1.323 4.281,1.323 false 3.948,2.135 4.344,2.135 false 3.948,3.083 4.365,3.083 false 4.146,0.344 4.375,0.344 false 0.625,1.417 0.938,1.573 0.313,0.156 10 false *a 1.469,3.385 1.781,3.542 0.313,0.156 10 false *b 3.667,0.094 3.979,0.25 0.313,0.156 10 false *c 0.646,2.219 0.958,2.375 0.313,0.156 10 false *d 2.354,2.26 2.667,2.417 0.313,0.156 10 false *a 3.667,1.063 3.979,1.219 0.313,0.156 10 false *d 3.875,3.427 4.188,3.583 0.313,0.156 10 false *a 3.979,0.25 4.292,0.406 0.313,0.156 10 false *a
*a Air Riveter *b Mandrel
*c Correct *d Incorrect


NOTICE:
·

If a rivet is not positioned perpendicular to the flange, it will bend the mandrel.

·

Do not pry the rivets with the riveter because the riveter will be damaged and the mandrel will be bent.

·

Do not tilt the riveter when installing a rivet because the parts will not be tightened firmly.

·

Make sure that the flanges of the fuel tank sub-assembly and No. 1 fuel tank protector are in firm contact while the rivets are being installed.




Hide 77213B 11.CONNECT FUEL TANK TO FILLER PIPE HOSE

a.
A310752C01
1.052,2.813 1.365,2.969 0.313,0.156 10 false *a 2.573,3.708 2.885,3.865 0.313,0.156 10 true *b
*a Upper
*b 90°


Connect the fuel tank to filler pipe hose to the fuel tank sub-assembly and tighten the clamp to secure it.

HINT:

Make sure the clamp bolt is within the area shown in the illustration.



b.
A315528

Engage the claw to install the fuel tank filler pipe protector onto the fuel tank to filler pipe hose.


Hide 12.INSTALL PARKING BRAKE CABLE ASSEMBLY

a.

Install the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly with the 4 bolts.

Torque:
6.0 N*m (61 kgf*cm, 53 in.*lbf)


Hide 77209F 13.CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

NOTICE:

Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


a.
A310290C02
1.823,2.844 1.948,2.844 1.948,2.844 2.031,2.594 false 2.156,3.219 2.271,3.219 2.271,3.219 2.417,3.552 false 2.583,3.625 2.708,3.25 2.708,3.25 2.833,3.25 false 2.021,4.406 2.021,4.021 false 1.771,4.406 2.177,4.406 2.177,4.406 2.177,4.021 false 2.906,4.323 2.906,4.135 2.906,4.135 2.635,3.948 false 1.656,2.75 1.969,2.906 0.313,0.156 10 false *a 1.573,4.323 1.885,4.479 0.313,0.156 10 false *b 2,3.125 2.313,3.281 0.313,0.156 10 false *c 2.833,4.344 3.146,4.5 0.313,0.156 10 false *d 2.875,3.156 3.188,3.313 0.313,0.156 10 false *a
*a Retainer
*b O-ring
*c Fuel Tube Connector
*d Fuel Pipe
V100135

Push
V100136

Push in


Connect the fuel tank main tube sub-assembly.

i.

Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.


ii.

Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.



Hide 75259A 14.CONNECT FUEL HOSE

NOTICE:

Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


a.
A321322C01
0.885,0.573 0.885,0.292 false 0.656,0.292 1.51,0.292 1.51,0.292 1.51,0.552 false 0.74,1.385 0.885,1.385 0.885,1.385 0.99,1.156 false 1.885,3.615 1.99,3.26 1.99,3.26 2.104,3.26 false 1.417,4.323 1.583,4.323 1.583,4.323 1.583,4.042 false 1.802,4.24 1.802,4.427 1.802,4.427 2.135,4.427 false 2.229,3.813 2.427,3.385 2.427,3.385 2.531,3.385 false 2.167,3.188 2.479,3.344 0.313,0.156 10 false *a 2.198,4.354 2.51,4.51 0.313,0.156 10 false *b 1.25,4.24 1.563,4.396 0.313,0.156 10 false *c 2.604,3.313 2.917,3.469 0.313,0.156 10 false *d 0.49,0.208 0.802,0.365 0.313,0.156 10 false *e 0.573,1.302 0.885,1.458 0.313,0.156 10 false *a
*a Retainer
*b Fuel Tube Connector
*c O-ring
*d Fuel Pipe
*e Claw
V100135

Push
V100136

Push in


Connect the fuel hose.

i.

Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.


ii.

Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.



Hide 15.CONNECT BREATHER TUBE FUEL HOSE

a.
A310750C01
1.031,2.667 1.344,2.823 0.313,0.156 10 false *a 2.521,3.021 2.833,3.177 0.313,0.156 10 false *b
*a Upper
*b 120°


Connect the breather tube fuel hose to the fuel pipe and tighten the clamp to secure it.

HINT:

Make sure the clamp bolt is within the area shown in the illustration.



Hide 77249 16.CONNECT FUEL EMISSION HOSE

a.

Connect the fuel emission hose to the fuel pipe.


Hide 17410 17.INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

Click hereEngine / Hybrid System>1ZR-FE INTAKE / EXHAUST>EXHAUST PIPE>INSTALLATION

Hide 77020A 18.INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

Click hereEngine / Hybrid System>1ZR-FE FUEL>FUEL PUMP>INSTALLATION

Hide 19.ADD FUEL