FUEL TANK (for Double Cab) INSTALLATION


  1. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. A01KFXA

      Install the fuel tank vent tube sub-assembly and a new gasket with the 6 bolts.

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

  2. INSTALL FUEL CUT OFF VALVE ASSEMBLY


    1. A01KFB6

      Install the 2 fuel tank support tube plates, 2 fuel cut off valve assembly and 4 new gaskets with the 8 screws.

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

      Install the evaporation hose with the 2 clips and 3 clamps.

  3. INSTALL FUEL SENDER GAGE ASSEMBLY


    1. A01KF29

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

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

  4. INSTALL FUEL TANK


    1. A01KG03E01

      Connect the fuel sender gage connector.

    2. Install the fuel tank band and fuel tank stay with the 10 nuts and 8 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf, for bolt }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for nut A }

  5. CONNECT FUEL EVAPORATIVE SEPARATOR FUEL HOSE


    1. A01KFDZ

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

  6. CONNECT FUEL MAIN TUBE


    1. A01KI3N

      Install the fuel main tube with the clip.

  7. CONNECT NO. 1 FUEL MAIN TUBE


    1. A01KEKD

      Install the No. 1 fuel main tube with the clip.

  8. ADD FUEL

  9. BLEED AIR FROM FUEL SYSTEM


    1. A01KETN

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

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  11. 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.

  12. INSTALL RH STEP SUB-ASSEMBLY


    1. A01KGCF

      Install the RH step sub-assembly with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  13. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH


    1. A01KGS6

      Install the fender side apron sub-assembly RH with the 5 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }