Fuel Injection System (HEV): Installation: Notes

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. Ref. 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.

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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.

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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.

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Tighten the bolts of the fuel tank band in the numerical order shown in the figure.
Tightening torque:

33 N.m (3.4 kgf-m, 24.3 ft-lb)

Fig 1: Fuel Tank Band Bolts Tightening Sequence
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Connect the fuel delivery tube to the fuel pipe assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE A) .

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Support the inverter with converter assembly 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.

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Tighten the bolts in the numerical order as 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)

Fig 2: Inverter And Converter Assembly Bolts (With Torque Specification)
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Connect the ground cable.
WARNING: Be sure to wear insulated gloves.

Tightening torque:

13 N.m (1.3 kgf-m, 9.6 ft-lb)

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Connect the hose - air breather. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE E) .

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Connect the connector (A) and install the bracket.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

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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)

Fig 3: Support - Sub Frame Bolts (With Torque Specification)
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Install the bolt and nut securing the HV air conditioning 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)

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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)

Fig 4: Inverter Center Water Pipe And Resolver Sensor Harness Bolts (With Torque Specification)
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Connect the fuel filler hose (A). Ref. 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. Ref. 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. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE H) .

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Install the rear differential. Ref. to DIFFERENTIALS>REAR DIFFERENTIAL (VA-TYPE)> INSTALLATION .
Install the tunnel stay.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

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Install the rear exhaust pipe and muffler.
Rear exhaust pipe:

Ref. to EXHAUST (H4DO (EXCEPT FOR HEV))>REAR EXHAUST PIPE>INSTALLATION .

Muffler:

Ref. to EXHAUST (H4DO (EXCEPT FOR HEV))>MUFFLER>INSTALLATION .
Install the floor under protector. Ref. to EXTERIOR/INTERIOR TRIM>FLOOR UNDER PROTECTOR>INSTALLATION .
Install the fuel tank protector and the cover of inverter with converter assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO(HEV))>FUEL TANK PROTECTOR>INSTALLATION .
Lower the vehicle.
Connect the connector to the fuel pump.
CAUTION: Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel pump and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.

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Install the service hole cover of fuel pump.

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Install the rear seat cushion. Ref. to SEATS>REAR SEAT>INSTALLATION .
Install the service disconnect plug. Ref. to HYBRID ELECTRIC VEHICLE>SERVICE PLUG>INSTALLATION .
Connect the battery ground terminal. Ref. to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .