RX400h · Service Manual ENGINE

INSTALLATION

Removal / installation


1. INSTALL FUEL TANK CUSHION

  1. A107252
    Install 8 new fuel tank cushions to the fuel tank.


2. INSTALL CLAMP

  1. A108221
    Install the clamp to the fuel tank.

  1. A107251
    Install the 2 fuel tube clamps of the fuel tank main tube to the fuel tank.


3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

  1. A107250
    Install the fuel tank main tube to the clamp.


4. INSTALL FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY

  1. A112360E01
    Connect the fuel tank to canister tube sub-assembly.

    1. Push in the fuel tube connector to the pipe and push down the retainer so that the claws engage.

      NOTICE:
      1. Check for damage or foreign objects on the connected part of the fuel pipe.
      2. After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

  1. A107249
    Install the fuel tank to canister tube to the fuel tank.


5. INSTALL FUEL TANK WIRE

  1. A107247
    Install the fuel tank wire.


6. INSTALL FUEL PUMP AND GAUGE WITH SUCTION TUBE

  1. A112353
    Install a new gasket on the fuel pump assembly.

  1. Install the fuel pump assembly.

  1. A108193
    Install the fuel tank vent tube set plate by aligning it with the cutout on the fuel pump assembly.

  1. Install the fuel tank vent tube set plate with the 8 bolts.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

  1. A112361E01
    Connect the fuel tank main tube with the tube joint clip and clamp.

    NOTICE:
    1. Check that there is no scratches or foreign objects on the connecting part.
    1. Check that the fuel tube joint is inserted securely.
    1. Check that the tube joint clip is on the collar of the fuel tube joint.
    1. After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

  1. A107243
    Connect the fuel tank wire connector.


7. INSTALL FUEL TANK ASSEMBLY

  1. A107242
    Operate the transmission jack, and install the fuel tank to the vehicle.

  1. Install the 2 fuel tank bands with the 4 bolts.

    Torque:
    39 N*m{ 400 kgf*cm , 29 ft.*lbf }


8. CONNECT FUEL TANK TO FILLER PIPE HOSE

  1. A107241
    Connect the fuel tank to filler pipe hose with the hose clamp.

  1. Connect the fuel tank breather hose with the hose clamp.


9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

  1. A112345E01
    Connect the fuel tank main tube sub-assembly.

    1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.

      NOTICE:
      1. Check for damage or foreign objects on the connected part.
      2. After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.


10. CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY

  1. A112348
    Install the fuel tank to canister tube sub-assembly to the clamp.

  1. A112362E01
    Connect the fuel tank to canister tube sub-assembly.

  1. Push the fuel tube connector into the pipe until the fuel tube connector makes a "click" sound.

    NOTICE:
    1. Check for any damage or foreign objects on the connected part.
    2. After connecting, check that the fuel tube connector and the pipe are securely connected by trying to pull them apart.


11. INSTALL CHARCOAL CANISTER PROTECTOR

  1. A112347
    Install the charcoal canister protector with the 3 bolts.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }


12. CONNECT FUEL TANK WIRE

  1. A107240
    Connect the fuel tank wire connector, and install it to the bracket.


13. INSTALL PARKING BRAKE CABLE ASSEMBLY NO.3

  1. A107237
    Install the parking brake cable assembly No.3 with the nut.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }


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

  1. A108198
    Install the fuel tank protector sub-assembly No.1 with the screw and the 4 grommets.


15. INSTALL FRONT FLOOR HEAT INSULATOR NO.3

  1. A107236
    Install the front floor heat insulator No.3 with the 5 nuts.

    Torque:
    4.9 N*m{ 50 kgf*cm , 43 in.*lbf }


16. INSTALL EXHAUST PIPE ASSEMBLY CENTER
(Click here)

17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

18. ADD FUEL

19. CHECK FOR FUEL LEAKS

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch to the ON position and turn the intelligent tester on.

    NOTICE:
    Do not start the engine.

  1. Select the Active Test mode on the intelligent tester to operate the fuel pump.

    HINT:
    Refer to the intelligent tester operator's manual for further details.

  1. Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.


20. CHECK FOR EXHAUST GAS LEAKS

21. PERFORM INITIALIZATION
Some systems need initialization after reconnecting the cable to the negative battery terminal. (Click here)
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