Diesel Data: Automotive Repair

Installation








2AZ-FE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL FUEL TANK CUSHION





(a) Install new fuel tank cushions onto the fuel tank.
2. INSTALL FUEL TANK VENT HOSE





(a) Install the fuel tank vent hose onto the fuel hose clamp.
3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Install the fuel tank main tube onto the fuel tank.
4. INSTALL FUEL TANK ASSEMBLY
(a) Set the fuel tank on a transmission jack.





(b) Operate the transmission jack, then install the fuel tank into the vehicle.





(c) Install the 2 No. 1 fuel tank bands with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
5. INSTALL FUEL TANK FILLER PIPE SUB-ASSEMBLY





(a) Connect the fuel tank filler pipe hose to the fuel tank.
NOTE: Make sure that the hose clamp is facing in the correct direction when installing.





(b) Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY





(a) Connect the fuel tank main tube.
(1) Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
NOTICE:
- Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector and pipe.

7. CONNECT BREATHER TUBE FUEL HOSE





(a) Connect the breather tube fuel hose to the hose clamp.





(b) Connect the breather tube fuel hose.
(1) Align the fuel hose connector with the pipe, then push the fuel hose connector in until the retainer makes a "click" sound to connect the breather tube fuel hose to the pipe.
NOTICE:
- Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
- After connecting the breather tube fuel hose, check that the fuel pump tube is securely connected by pulling on the fuel tube connector and pipe.

8. CONNECT FUEL TANK VENT HOSE





(a) Connect the fuel tank vent hose.
(1) Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
(2) Slide the retainer of the fuel tube connector to lock the claws as shown in the illustration.
NOTICE:
- Check that there are no scratches or foreign objects around the connecting surfaces of the fuel tube connector and pipe before performing this work.
- After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling on the fuel tube connector.

9. INSTALL NO. 1 FUEL TANK PROTECTOR





(a) Install the No.1 fuel tank protector with the 4 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
10. CONNECT PARKING BRAKE CABLE





(a) Install the parking cables with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
11. INSTALL CENTER EXHAUST PIPE ASSEMBLY
HINT: Installation.

12. ADD FUEL
13. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE
(a) Install the fuel suction with pump and gauge tube assembly to the fuel tank Installation.
14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation
15. INSPECT FOR FUEL LEAK Testing and Inspection
16. INSPECT FOR EXHAUST GAS LEAK