FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK CUSHION


    1. A01W20O

      Install 5 new No. 1 fuel tank cushions as shown in the illustration.

  2. INSTALL FUEL TANK BREATHER HOSE


    1. A01W2Q4E02
      Text in Illustration
      *a UP
      *b 180°
      *c 2 to 7 mm (0.0787 to 0.276 in.)
      *d 0 to 3 mm (0 to 0.118 in.)

      Install the fuel tank breather hose, then fit it with the clamp as shown in the illustration.

  3. INSTALL NO. 1 FUEL TUBE CLAMP


    1. Install the No. 1 fuel tube clamp.

  4. CONNECT NO. 2 FUEL TUBE CLAMP


    1. Connect the No. 2 fuel tube clamp and install the charcoal canister outlet hose.

  5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Install the fuel tank main tube sub-assembly to the No. 1 fuel tube clamp.

  6. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Support the fuel tank sub-assembly using an engine lifter.

    2. Raise the engine lifter, then install the fuel tank sub-assembly to the vehicle.

      Note


      • Do not drop the fuel tank sub-assembly.

      • When installing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

    3. Tighten the 4 bolts of the 2 fuel tank bands.

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

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01W22IE01
      Text in Illustration
      *1 Retainer
      *a UP
      *b 90°
      *c

      120°

      (Retainer Area)
      B001OAO Push

      Push in the fuel tank to filler pipe hose connector to the fuel tank sub-assembly and push in the retainer so that the claws engage.

      Note


      • Check that there are no scratches or foreign matter around the connected parts of the fuel tank to filler pipe hose connector and fuel tank sub-assembly before performing this work.

      • After connecting the fuel tank to filler pipe hose, check that the fuel tank to filler pipe hose is securely connected by pulling on the fuel tank to filler pipe hose connector.

  8. CONNECT FUEL TANK BREATHER HOSE


    1. A01VZFZE02
      Text in Illustration
      *a Up
      *b 135°

      Connect the fuel tank breather hose, then fit it with the clamp as shown in the illustration.

  9. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A01W520E01
      Text in Illustration
      *1 Fuel Emission Hose
      *2 No. 1 Charcoal Canister Outlet Hose
      *a Up
      *b 120°
      *c 120°

      Connect the No. 1 charcoal canister outlet hose, then fit it with the clip as shown in the illustration.

  10. CONNECT FUEL EMISSION HOSE


    1. Connect the fuel emission hose, then fit it with the clip as shown in the illustration.

  11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01W0STE03
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Pipe
      *4 O-ring
      B001O8N Push

      Push in the fuel tube connector to the fuel pipe and push up the retainer so that the claws engage.

      Note


      • Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe before starting this step.

      • After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

  12. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Install the No. 1 fuel tank protector with the 3 clips.

  13. INSTALL REAR NO. 1 STABILIZER BAR BRACKET


    1. Install the 2 rear No. 1 stabilizer bar brackets with the 4 nuts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  14. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 3 parking brake cable assembly with the nut.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  15. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 2 parking brake cable assembly with the nut.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  16. INSTALL NO. 1 FLOOR UNDER COVER

    Click here

  17. INSTALL NO. 2 FLOOR UNDER COVER

    Click here

  18. INSTALL CENTER EXHAUST PIPE ASSEMBLY

    Click here

  19. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  20. ADD FUEL

  21. INSPECT FOR EXHAUST GAS LEAK