FUEL TANK(w/o Canister Pump Module) INSTALLATION

PROCEDURE

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

   
   

   1. Install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly.

2. INSTALL FUEL TUBE CLAMP BRACKET

   
   

   1. Install the 2 fuel tube clamp brackets to the fuel tank assembly.

3. INSTALL FUEL TUBE GROMMET

   
   

   1. Install the fuel tube grommet to the fuel tank assembly.

4. INSTALL NO. 4 FUEL TUBE CLAMP

   
   

   1. Install the No. 4 fuel tube clamp to the fuel tank assembly.

5. INSTALL NO. 3 FUEL TUBE CLAMP

   
   

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

6. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

   
   

   1. Attach the 6 clamps and install the fuel tank main tube sub-assembly to the fuel tank assembly.

7. INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY

   
   

   1. Install a new fuel tank breather tube gasket to the No. 1 fuel tank breather tube sub-assembly.

   2. Install the No. 1 fuel tank breather tube sub-assembly to the fuel tank assembly with the 4 screws.

      Torque:

      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

8. INSTALL FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY

   
   

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

      Click here

9. INSTALL FUEL TANK ASSEMBLY

   
   

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

   2. Using an engine lifter, slowly raise the fuel tank assembly, and then install the fuel tank assembly.

      Note

      
      

      • Slowly raise the fuel tank assembly while being careful not to drop it.

      • Do not allow the fuel tank assembly to contact the vehicle, especially the rear differential carrier assembly.

   3. 

      *A	for RH Side
      *B	for LH Side
      *a	Torque Wrench Fulcrum Length

      Install the 2 fuel tank bands and 4 bolts.

      SST

      09961-00950

      Torque
      Specified tightening torque
      45 N*m (459 kgf*cm, 33 ft.*lbf)

      Tech Tips

      
      

      • Using SST and a union nut wrench (14 mm), install the rear side of the fuel tank band.

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + SST (fulcrum length of 150 mm (5.906 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 22.8 N*m (232 kgf*cm, 17 ft.*lbf)

10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    
    

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

       Click here

11. CONNECT NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY

    
    
    1. 

       *a

       Top

       Connect the No. 1 fuel tank breather tube sub-assembly with the hose clamp.

       Tech Tips

       Make sure the hose clamp is oriented as shown in the illustration.

12. CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY

    
    

    1. Connect the fuel tank to canister tube sub-assembly.

       Click here

13. CONNECT FUEL TANK TO FILLER PIPE HOSE

    
    
    1. 

       *a	Top
       *b	Paint Mark

       Connect the fuel tank to filler pipe hose with the hose clamp.

       Tech Tips

       Make sure the hose clamp is oriented as shown in the illustration.

14. INSTALL REAR LOWER SUSPENSION MEMBER STOPPER LH

    
    

    1. 

       Install the rear lower suspension member stopper LH with the 3 bolts.

       Torque:

       for bolt A

       135 N*m  { 1377 kgf*cm, 100 ft.*lbf }

       for bolt B

       19 N*m  { 194 kgf*cm, 14 ft.*lbf }

15. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

16. ADD FUEL

17. INSTALL NO. 2 FUEL SENDER GAUGE ASSEMBLY

    Click here

18. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

19. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

    Click here

20. INSTALL NO. 2 DECK BOARD

    Click here