FUEL TANK(w/o Canister Pump Module) INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 FUEL TANK CUSHION


    1. Install 2 new No. 2 fuel tank cushions to the fuel tank assembly.

  2. INSTALL NO. 6 FUEL TANK CUSHION


    1. Install a new No. 6 fuel tank cushion to the fuel tank assembly.

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


    1. Engage the clamp to install the No. 1 fuel evaporation tube sub-assembly to the fuel tank assembly.

  4. INSTALL CHARCOAL CANISTER OUTLET HOSE


    1. Engage the clamp to install the charcoal canister outlet hose to the fuel tank assembly.

  5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Engage the clamp to install the fuel tank main tube sub-assembly to the fuel tank assembly.

  6. 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.

    B0070IK

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

      Note

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

    2. B0070G8N01

      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 }

      Note


      • 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.

  7. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Connect the fuel tank main tube sub-assembly to the fuel pipe.

      Click here

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


    1. B006Y4PC01
      *a 120°
      *b Up
      *c 2.0 to 7.0 mm (0.0787 to 0.276 in.)
      *d Paint Mark

      Connect the No. 1 fuel evaporation tube sub-assembly to the fuel pipe and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  9. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B006WWFC01
      *a 120°
      *b Up
      *c 0 to 3.0 mm (0 to 0.118 in.)
      *d Clamp End
      *e Stopper
      *f +/- 2.0 mm (0.0787 in.)
      *g Paint Mark (Fuel Tank To Filler Pipe Hose)
      *h Protrusion (Fuel Tank Assembly)

      Connect the fuel tank to filler pipe hose to the fuel tank assembly and tighten the clamp to secure it.

      Tech Tips


      • Make sure the clamp and fuel tank to filler pipe hose are positioned within the area shown in the illustration.

      • Make sure that the clamp end is positioned within 2.0 mm (0.0787 in.) of the stopper.

  10. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. B00717AC01
      *a 120°
      *b Up
      *c 0 to 3.0 mm (0 to 0.118 in.)
      *d 2.0 to 7.0 mm (0.0787 to 0.276 in.)

      Connect the fuel tank breather tube sub-assembly to the fuel tank filler pipe assembly and tighten the clamp to secure it.

      Tech Tips

      Make sure the clamp and fuel tank breather tube sub-assembly are positioned within the area shown in the illustration.

  11. CONNECT CHARCOAL CANISTER OUTLET HOSE


    1. Connect the charcoal canister outlet hose to the fuel tank filler pipe assembly.

  12. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Install the No. 1 fuel tank protector to the fuel tank assembly with the 4 clips.

  13. INSTALL CENTER EXHAUST PIPE ASSEMBLY

    Click here

  14. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  15. ADD FUEL