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:
      1.5 N*m  { 15 kgf*cm, 13 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 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. A01CJGD

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

    2. Install the fuel tank bands and the fuel tank stays with the 12 nuts and 8 bolts.

      Torque:
      61 N*m  { 622 kgf*cm, 45 ft.*lbf, for bolt }
      13 N*m  { 130 kgf*cm, 9 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. A01CIXH

      Connect the drain hose to the air bleed plug.

    2. Loosen the fuel filter's air bleed plug.

      Note


      • Do not use any tools.

      • Do not allow any fuel to spill.

      • If any fuel spills on any part of the engine, wipe it clean with a piece of cloth.

    3. A01CGRK

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

    4. A01CHZ4

      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. Connect the intelligent tester to the DLC3.

      2. Start the engine.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop or Start

        • Fuel pressure inside common rail is pressurized to specified value and engine speed is increased to 2000 rpm when Start is selected.

        • Above conditions preserved while Start is selected.