Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 2 FUEL TANK CUSHION

(a) Install a new No. 2 fuel tank cushion to the fuel tank assembly.

2. INSTALL NO. 3 FUEL TANK CUSHION

(a) Install 2 new No. 3 fuel tank cushions to the fuel tank assembly.

3. INSTALL NO. 1 FUEL TANK CUSHION

(a) Install a new No. 1 fuel tank cushion to the fuel tank assembly.

4. INSTALL NO. 4 FUEL TANK CUSHION

(a) Install 2 new No. 4 fuel tank cushions to the fuel tank assembly.

5. INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY

(a) Install the fuel return vent tube sub-assembly to the fuel tank assembly.

6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Engage the clamp to install the fuel tank main tube sub-assembly to the fuel tank assembly.

7. INSTALL FUEL TANK ASSEMBLY

CAUTION:

The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

(a) Set the fuel tank assembly on an engine lifter.

NOTICE:

Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

(b) Using the engine lifter, slowly raise the fuel tank assembly, and then install the fuel tank assembly, No. 1 fuel tank band sub-assembly LH and No. 1 fuel tank band sub-assembly RH with the 4 bolts in the order shown in the illustration. Torque: 45 N·m {459 kgf·cm, 33 ft·lbf} NOTICE: Be careful not to drop the fuel tank assembly. When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.

(c) Engage the clamp to connect the fuel cut off valve with tube assembly to the fuel tank vent hose sub-assembly.

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(d) Connect the No. 1 fuel tank breather tube sub-assembly to the fuel pipe.

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8. CONNECT INLET FUEL TANK PIPE SUB-ASSEMBLY

(a) Connect the inlet fuel tank pipe sub-assembly to the fuel tank assembly.

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9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

(a) Connect the fuel tank main tube sub-assembly to the fuel pipe.

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

(a) Install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly with the 4 clips.

11. INSTALL NO. 2 FUEL TANK PROTECTOR

(a) Install the No. 2 fuel tank protector to the No. 1 fuel tank band sub-assembly RH with the nut.

Torque:

10.5 N·m {107 kgf·cm, 8 ft·lbf}

12. INSTALL NO. 1 FLOOR UNDER COVER

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13. INSTALL NO. 2 FLOOR UNDER COVER

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14. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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15. INSTALL FUEL TANK VENT TUBE ASSEMBLY

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16. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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17. ADD FUEL

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