FUEL TANK(w/o Canister Pump Module) INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Install the fuel evaporation tube sub-assembly to the fuel tank assembly.

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  2. INSTALL NO. 2 FUEL TUBE CLAMP


    1. Install the 2 No. 2 fuel tube clamps to the fuel tank assembly.

  3. INSTALL CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY


    1. Connect the 2 clamps and install the charcoal canister outlet tube sub-assembly to the 2 No. 2 fuel tube clamps.

  4. INSTALL NO. 5 FUEL TUBE CLAMP


    1. Install the No. 5 fuel tube clamp to the fuel tank assembly.

  5. INSTALL NO. 4 FUEL TUBE CLAMP


    1. Install the 3 No. 4 fuel tube clamps to the fuel tank assembly.

  6. INSTALL NO. 3 FUEL TUBE CLAMP


    1. Install the No. 3 fuel tube clamp to the fuel tank assembly.

  7. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Connect the 5 clamps and install the No. 1 fuel evaporation tube sub-assembly to the No. 3 fuel tube clamp, 3 No. 4 fuel tube clamps and No. 5 fuel tube clamp.

  8. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Connect the 5 clamps and install the fuel tank main tube sub-assembly to the No. 3 fuel tube clamp, 3 No. 4 fuel tube clamps and No. 5 fuel tube clamp.

  9. INSTALL FUEL SENDER GAUGE ASSEMBLY

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  10. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP

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  11. INSTALL FUEL TANK VENT TUBE SET PLATE

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  12. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

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  13. CONNECT FUEL EMISSION HOSE

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  14. INSTALL FUEL TANK ASSEMBLY


    1. Set the fuel tank assembly on an engine lifter with attachments.

    2. Raise the engine lifter.

      Note

      Be careful not to cut the fuel gauge wire.

    3. Attach the 3 clamps to No. 3 fuel tube clamp, No. 4 fuel tube clamp and No. 5 fuel tube clamp and connect the fuel gauge wire to the fuel tank assembly.

    4. Connect the 2 connectors to the fuel sender gauge assembly and fuel suction tube assembly with pump.

    5. Install the 2 No. 2 fuel tank band sub-assemblies with the 4 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

    6. Install the No. 1 fuel tank band sub-assembly with the 2 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

    7. Connect the 3 clamps to the 2 No. 4 fuel tube clamps and the bracket on the vehicle side.

  15. CONNECT NO. 3 FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. Connect the No. 3 fuel tank breather tube sub-assembly to the fuel tank assembly.

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  16. CONNECT CHARCOAL CANISTER OUTLET TUBE SUB-ASSEMBLY


    1. Connect the charcoal canister outlet tube sub-assembly to the fuel tank breather tube, and slide the clamp to secure the hose.

    2. Attach the clamp and connect the fuel tank vent hose sub-assembly to the No. 2 fuel tank band sub-assembly.

  17. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B008HI3C02
      *a Top
      *b Underside of fuel tank assembly
      *c Stopper
      *d Protrusion

      Connect the fuel tank to filler pipe hose to the fuel tank assembly, then tighten the hose clamp.

      Tech Tips

      Make sure that the fuel tank to filler pipe hose and hose clamp are oriented as shown in the illustration.

  18. INSTALL FUEL HOSE PROTECTOR


    1. Attach the claw, then install the fuel hose protector to the fuel tank to filler pipe hose.

  19. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Connect the 2 fuel tank main tube sub-assemblies to the 2 fuel pipes.

      Click here

  20. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Connect the No. 1 fuel evaporation tube sub-assembly to the fuel tank to canister tube, and slide the clamp to secure the hose.

  21. INSTALL NO. 2 FLOOR UNDER COVER


    1. Attach the clip and install the No. 2 floor under cover with the 2 nuts.

  22. INSTALL FRONT FLOOR COVER CENTER LH


    1. Install the front floor cover center LH with the bolt, 2 nuts and 6 clips.

    2. Tighten the nut.

  23. ADD FUEL

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  25. INSPECT FOR FUEL LEAK

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