Fuel Tank: Installation
WARNING:
- Place "NO OPEN FLAMES" signs near the working area.
- The hybrid system includes a high voltage circuit. Mishandling could cause accidents such as electric shock or leak. Always check "WARNING (HYBRID SYSTEM)" and perform the proper operation. Refer to PRECAUTION/WARNING>WARNING (HYBRID SYSTEM) .
- Install the insulator and protector to the fuel tank.
- Install the insulator holder (A) to the lower insulator (C) and set it on the fuel tank.
- Install the upper insulator (B) to the insulator holder (A).CAUTION: Be sure to fix the insulator holder and the insulator without looseness as shown in the figure.
- Set the protector (B) on the fuel tank and install the clip (A).CAUTION: Be sure to insert the clip all the way to the end.
- Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.CAUTION: A helper is required to perform this work.
- Tighten the bolts of the fuel tank band in the order shown in the figure.
Tightening torque:
33 N.m (3.4 kgf-m, 24.3 ft-lb)
- Connect the fuel delivery tube to the fuel pipe assembly. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE A) .
- Support the inverter assembly (with converter) with the transmission jack and temporarily tighten the bolt.WARNING: Be sure to wear insulated gloves.CAUTION: A helper is required to perform this work.
- Tighten the bolts in the order shown in the figure.WARNING: Be sure to wear insulated gloves.
Tightening torque:
T1: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
T2: 23 N.m (2.3 kgf-m, 17.0 ft-lb)
- Connect the ground cable.WARNING: Be sure to wear insulated gloves.
Tightening torque:
13 N.m (1.3 kgf-m, 9.6 ft-lb)
- Connect the hose - air breather. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE E) .
- Connect the connector (A) and install the bracket.
Tightening torque:
18 N.m (1.8 kgf-m, 13.3 ft-lb)
- Install the support - sub frame (A).
Tightening torque:
T1: 70 N.m (7.1 kgf-m, 51.6 ft-lb)
T2: 145 N.m (14.8 kgf-m, 106.9 ft-lb)
- Connect the connector (B) and install the bracket.
Tightening torque:
T3: 18 N.m (1.8 kgf-m, 13.3 ft-lb)
- Install the bolt and nut securing the air conditioner wire (A) and power cable assembly (B).WARNING: Be sure to wear insulated gloves.
Tightening torque:
7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
- Install the bolt and clip (A) securing the inverter center water pipe and the resolver sensor harness.
Tightening torque:
T1: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
T2: 18 N.m (1.3 kgf-m, 9.6 ft-lb)
- Connect the fuel filler hose (A). Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>FUEL FILLER HOSE CONNECTION .
- Connect the circulate tube (B) to the fuel tank. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE F) .
- Connect the vent tube (C) to the electric vent solenoid valve assembly. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE H) .
- Install the rear differential. Refer to DIFFERENTIALS>REAR DIFFERENTIAL (VA-TYPE)>INSTALLATION .
- Install the tunnel stay.
Tightening torque:
18 N.m (1.8 kgf-m, 13.3 ft-lb)
- Install the rear exhaust pipe and muffler.
Rear exhaust pipe:
Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>REAR EXHAUST PIPE>INSTALLATION .
Muffler:
Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>MUFFLER>INSTALLATION .
- Install the floor under protector. Refer to EXTERIOR/INTERIOR TRIM>FLOOR UNDER PROTECTOR>INSTALLATION .
- Install the fuel tank protector and inverter assembly (with converter) cover. Refer to FUEL INJECTION (FUEL SYSTEMS) (H4DO (HEV))>FUEL TANK PROTECTOR>INSTALLATION .
- Lower the vehicle.
- Connect the connector to the fuel pump.
- Install the service hole cover of fuel pump.
- Install the rear seat cushion. Refer to SEATS>REAR SEAT>INSTALLATION .
- Install the service disconnect plug. Refer to HYBRID ELECTRIC VEHICLE>SERVICE PLUG>INSTALLATION .
- Connect the battery ground terminal. Refer to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .