Installation

2AZ-FE FUEL: FUEL TANK: INSTALLATION

INSTALLATION

1. INSTALL NO. 1 FUEL TANK CUSHION (for 4WD)





(a) Install new No. 1 fuel tank cushions onto the fuel tank.
2. INSTALL NO. 3 FUEL TANK CUSHION (for 4WD)





(a) Install new No. 3 fuel tank cushions onto the fuel tank.
3. INSTALL FUEL TANK CUSHION (for 2WD)





(a) Install new fuel tank cushions onto the fuel tank.
4. INSTALL FUEL TANK VENT HOSE (for 4WD)





(a) Install the fuel tank vent hose.
5. INSTALL FUEL TANK VENT HOSE (for 2WD)





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





(a) Install the fuel tank main tube onto the fuel tank.
7. INSTALL FUEL TANK ASSEMBLY (for 4WD)
(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)
8. INSTALL FUEL TANK ASSEMBLY (for 2WD)
(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)
9. 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 the correct direction when installing.





(b) Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe.
10. 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.

11. CONNECT BREATHER TUBE FUEL HOSE





(a) Connect the breather tube fuel hose.





(b) Connect the breather tube fuel hose.
(1) Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube 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.
(2) Install the checker onto the pipe.
12. CONNECT FUEL TANK VENT HOSE (for Torsion Beam Type Suspension)





(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.

13. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY (for Double Wishbone Type Suspension)
14. INSTALL CHARCOAL CANISTER ASSEMBLY (for Double Wishbone Type Suspension)
HINT:
- Installation for 4WD
- Installation for 2WD

15. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY (for 4WD)





(a) Install the fuel tank protector sub-assembly with the 4 bolts and 2 nuts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
16. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY (for 2WD)





(a) Install the fuel tank protector sub-assembly with the 4 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
17. CONNECT PARKING BRAKE CABLE





(a) Install the parking brake cables with the 4 bolts.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
18. TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)
19. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
20. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 4WD)
HINT: Installation

21. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for 2WD)
HINT: Installation

22. ADD FUEL
23. INSTALL FUEL SENDER GAUGE RH ASSEMBLY (for 4WD) Installation
24. INSTALL FUEL SUCTION TUBE ASSEMBLY
(a) Install the fuel suction tube assembly to the fuel tank assembly Reassembly.
25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
26. INSPECT FOR FUEL LEAK Testing and Inspection
27. INSPECT FOR EXHAUST GAS LEAK
28. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER (for 4WD) Installation