FUEL TANK INSTALLATION


  1. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. With a new gasket, install the fuel tank bent tube with the 6 bolts.

      Torque:
      5.0 N*m  { 50 kgf*cm, 44 in.*lbf }

  2. INSTALL FUEL CUT OFF VALVE ASSEMBLY


    1. With a new gasket, install the fuel cut-off valve assembly with the 6 bolts.

      Torque:
      3.5 N*m  { 35 kgf*cm, 30 in.*lbf }

  3. INSTALL FUEL SENDER GAGE ASSEMBLY


    1. With a new gasket, install the fuel sender gauge assembly with the 5 screws.

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

  4. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Install the tank and fuel tank band.

      Torque:
      13 N*m  { 132 kgf*cm, 95 ft.*lbf }

  5. CONNECT FUEL EVAPORATIVE SEPARATOR FUEL HOSE

  6. CONNECT FUEL RETURN TUBE FUEL HOSE

  7. CONNECT FUEL MAIN TUBE FUEL HOSE

  8. CONNECT FUEL SENDER GAUGE CONNECTOR

  9. ADD FUEL

  10. CONNECT BATTERY NEGATIVE TERMINAL

  11. BLEED FUEL


    1. Move the priming pump of the fuel filter up and down until it becomes hard.

  12. INSPECT FUEL LEAK

    CAUTION:


    • During ACTIVE TEST mode, engine speed goes high and combustion noise becomes loud, so pay attention.

    • During ACTIVE TEST mode, fuel becomes high pressure, so take much care not to expose your eyes, hands, or body to the fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine stops.

      If there is fuel leakage, replace those parts.

    2. While cranking or starting the engine, check that there are no leaks from any part of the fuel system.

      If there is fuel leakage, replace those parts.

    3. Disconnect the return hose from the common rail.

    4. While cranking the engine, check fuel leakage from the return pipe.

      If there is fuel leakage, replace the common rail assembly Click here.

    5. A01KFQVE01
      Text in Illustration
      *1 Intelligent Tester

      Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch ON.

    7. Select the FUEL LEAK test of ACTIVE TEST mode on the intelligent tester.

    8. If you have no intelligent tester, depress the accelerator pedal quickly and fully to increase the engine speed at maximum and keep it for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      If the leakage from the return pipe is less than 10 cc (0.6 cu in.) in a minute, it is acceptable.

      If there is fuel leakage, replace those parts.

    10. Reconnect the return hose to the common rail.