FUEL TANK (for Single Cab) INSTALLATION


  1. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. A01KHSX

      Install the fuel tank vent tube sub-assembly and a new gasket with the 6 bolts (for 60 Litter Tank).

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }
    2. A01KFXA

      Install the fuel tank vent tube sub-assembly and a new gasket with the 6 bolts (for 80 Litter Tank).

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

  2. INSTALL FUEL CUT OFF VALVE ASSEMBLY


    1. A01KI7G

      Install the fuel tank support tube plate, fuel cut off valve assembly and 2 new gaskets with the 5 screws (for 60 Litter Tank).

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    2. A01KFB6

      Install the 2 fuel cut off valve assembly and 4 new gaskets with the 8 screws (for 80 Litter Tank).

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    3. A01KIA2

      Install the evaporation hose with the 2 clips and 3 clamps (for 80 Litter Tank).

  3. INSTALL FUEL SENDER GAGE ASSEMBLY


    1. A01KHCP

      Install the fuel sender gage assembly and a new gasket with the 5 screws (for 60 Litter Tank).

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }
    2. A01KF29

      Install the fuel sender gage assembly and a new gasket with the 5 screws (for 80 Litter Tank).

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

  4. INSTALL FUEL TANK


    1. A01KFOB

      Install the fuel tank and fuel tank band with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  5. CONNECT FUEL EVAPORATIVE SEPARATOR FUEL HOSE


    1. A01KGWQ

      Install the fuel evaporative separator fuel hose with the clip (for 60 Litter Tank).

    2. A01KFDZ

      Install the fuel evaporative separator fuel hose with the clip and clamp (for 80 Litter Tank).

  6. CONNECT FUEL MAIN TUBE


    1. A01KE9G

      Install the fuel main tube with the clip (for 60 Litter Tank).

    2. A01KI3N

      Install the fuel main tube with the clip (for 80 Litter Tank).

  7. CONNECT NO. 1 FUEL MAIN TUBE


    1. A01KGOA

      Install the No.1 fuel main tube with the clip (for 60 Litter Tank).

    2. A01KEKD

      Install the No. 1 fuel main tube with the clip (for 80 Litter Tank).

  8. CONNECT FUEL SENDER GAGE CONNECTOR


    1. A01KGY5

      Connect the fuel sender gage connector and harness clamp (for 60 Litter Tank).

    2. A01KG5E

      Connect the fuel sender gage connector and harness clamp (for 80 Litter Tank).

  9. ADD FUEL

  10. BLEED AIR FROM FUEL SYSTEM


    1. A01KETN

      Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    6.4 N*m  { 65 kgf*cm, 56 in.*lbf }

  12. INSPECT FOR FUEL LEAK


    1. PERFORM ACTIVE TEST


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch ON.

      3. Turn the intelligent tester ON.

      4. Start the engine.

      5. Enter the following menus: Powertrain / ECD / Active Test.

      6. 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/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

      7. Make sure that there is no fuel leakage in the fuel system during the Active Test.