Installation

2AZ-FE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY






(a) Install the fuel tank main tube sub-assembly onto the fuel tank.






2. INSTALL FUEL TANK CUSHION
(a) Install a new No. 1 fuel tank cushion and 3 No. 2 fuel tank cushion as shown in the illustration.
3. INSTALL FUEL TANK ASSEMBLY
(a) Support the fuel tank using an mission jack.






(b) Temporary install the fuel tank with 4 new bolts.
(c) Tighten the 4 bolts in the order shown in the illustration.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)






(d) Connect the parking brake cable assembly with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
4. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY






(a) Align the fuel tube connector with the pipe, push the fuel tube connector in until the retainer makes a click sound, then lock the connector cover.
- Check that there are no scratches or foreign matter on the disconnected parts of the fuel tube connector and pipe before performing this work.
- After connecting, pull the pipe and fuel tube connector to make sure that they are securely connected.





5. CONNECT NO. 6 FUEL TANK BREATHER TUBE
(a) Align the fuel tube connector with the pipe, push the fuel tube connector in until the retainer makes a click sound, then lock the connector cover.
NOTICE:
- Check that there are no scratches or foreign matter on the disconnected parts of the fuel tube connector and pipe before performing this work.
- After connecting, pull the pipe and fuel tube connector to make sure that they are securely connected.





6. CONNECT FUEL TANK TO FILLER PIPE HOSE
(a) Connect the fuel tank to filler pipe hose with the clamp.
(b) Tighten the clamp bolt.






7. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
(a) Install the No. 1 fuel tank protector sub-assembly with the 3 bolts and nut.
HINT: Tighten the bolts and nut in the order shown in the illustration.

Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
8. INSTALL NO. 2 CENTER EXHAUST PIPE ASSEMBLY





(a) Using vernier calipers, measure the free length of the compression springs.
Minimum length:
38.5 mm (1.516 in.)
If the length is not as specified, replace the compression spring.






(b) Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold and center exhaust pipe assembly.
- Install the exhaust pipe gasket in the correct direction.
- Do not damage the outer surface of the exhaust pipe gasket.
- Do not reuse the exhaust pipe gasket.
- Do not push in the gasket with the exhaust pipe when connecting it.

(c) Install the new exhaust pipe gasket onto the No. 2 exhaust pipe gasket.






(d) Install the No. 2 center exhaust pipe assembly with the 4 bolts and 2 compression spring.
9. INSTALL REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY






(a) Install the rear floor side member brace sub-assembly with the 4 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
10. INSTALL REAR FLOOR SIDE MEMBER COVER LH






(a) Install the rear floor side member cover LH with the nut, grommet and 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
11. INSTALL REAR FLOOR SIDE MEMBER COVER RH






(a) Install the rear floor side member cover RH with the nut, grommet and 2 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
12. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY Installation

13. INSTALL FUEL PUMP GAUGE RETAINER Installation

14. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY Installation

15. INSTALL REAR FLOOR SERVICE HOLE COVER Installation

16. ADD FUEL
17. INSPECT FOR FUEL LEAK Vehicle Damage Warnings
18. INSTALL REAR SEAT CUSHION WITH COVER PAD SUB-ASSEMBLY Installation