FUEL TANK INSTALLATION


  1. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. A01CIKN

      Install the fuel tank vent tube sub-assembly and a new gasket with the 5 bolts.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  2. INSTALL FUEL CUT OFF VALVE ASSEMBLY


    1. A01CJ9U

      Install the 2 fuel tank support tube plates, the 2 fuel cut off valve assemblies and the 4 new gaskets with the 10 screws.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    2. A01CJ0E

      Install the evaporation hose with the 2 clips and clamp.

  3. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. A01CGSG

      Install the fuel sender gauge assembly and a new gasket with the 5 screws.

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

  4. INSTALL FUEL TANK ASSEMBLY


    1. A01CHS7E01

      While supporting the fuel tank, connect the fuel sender gauge connector.

    2. Install the fuel tank band and the fuel tank stay with the 12 nuts and 8 bolts.

      Torque:
      61 N*m  { 622 kgf*cm, 45 ft.*lbf, for bolt }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for nut A }

  5. CONNECT FUEL EVAPORATIVE SEPARATOR FUEL HOSE


    1. A01CGSH

      Install the fuel evaporative separator fuel hose with the clip and clamp.

  6. CONNECT NO. 2 RETURN TUBE FUEL HOSE


    1. A01CHOO

      Install the No. 2 return tube fuel hose with the clip.

  7. CONNECT NO. 2 MAIN TUBE FUEL HOSE


    1. A01CI42

      Install the No. 2 main tube fuel hose with the clip.

  8. ADD FUEL

  9. BLEED AIR FROM FUEL SYSTEM


    1. A01CGS9

      Loosen the fuel filter's air bleed plug.

    2. A01CGKM

      While covering the drain pipe with a shop rag or a piece of cloth, press and release the priming pump until the fuel from the drain pipe does not have any bubbles.

    3. A01CIWK

      Tighten the air bleed plug.

      Note

      Do not use any tools.

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  11. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

        Note

        Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

      2. Connect the intelligent tester to the DLC3.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Select the following menu items: Powertrain / Engine / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizing common rail internal fuel pressure, and checking for fuel leaks Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected

        • Above conditions preserved while test is ON