FUEL TANK INSTALLATION


  1. INSTALL FUEL PUMP ASSEMBLY


    1. A01BGHUE01

      Install the fuel pump assembly and fuel bent tube set plat with the 8 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  2. CONNECT FUEL TANK WIRE


    1. A01BBI4E01

      Connect the fuel tank wire connector to the fuel pump assembly.

  3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01BHC4E01

      connect the fuel tank main tube with the tube joint clip.

  4. CONNECT FUEL TANK RETURN TUBE


    1. A01BASDE01

      Connect the fuel tank return tube with the tube joint clip.

  5. CONNECT FUEL EVAPORATION TUBE SUB-ASSEMBLY NO.1


    1. A01BF65E01

      Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a 'click' sound. In case that the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.

      Note


      • Check that there is any damage or foreign objects in the connected part of the pipe.

      • After finishing the connection, check if the pipe and the connector are securely connected by pulling them.

  6. INSTALL FUEL TANK ASSEMBLY


    1. A01BAPVE01

      Using the transmission jack, install the 2 fuel tank band sub-assemblies and fuel tank assembly with the 6 bolts.

      Torque:
      38 N*m  { 398 kgf*cm, 28 ft.*lbf }

    2. Connect the parking brake cable No.3 with the bolt.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  7. CONNECT FUEL TANK HOSE NO.3


    1. A01BASME01

      Connect the fuel hose No.3, and tighten the clamp bolt.

  8. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY NO.1


    1. A01BAK9E01

      Connect the fuel tank breather tube and clip.

  9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01BD7ME01

      Connect the fuel tank main tube sub-assembly and clamp. Click here

  10. CONNECT FUEL TANK RETURN TUBE


    1. A01BI3YE01

      Connect the fuel return tube sub-assembly. Click here

  11. CONNECT FUEL EVAPORATION TUBE SUB-ASSEMBLY NO.1


    1. A01BDYZE01

      Disconnect fuel evaporation tube sub-assembly. Click here

  12. CONNECT FUEL TANK WIRE


    1. A01BG6SE01

      Connect the fuel tank wire.

  13. INSTALL PROPELLER SHAFT ASSEMBLY

    Tech Tips


    • Propeller shaft assembly for Super Long Wheelbase Click here

    • Propeller shaft assembly for Long Wheelbase Click here

  14. BLEED FUEL LINE


    1. Check that the battery voltage is above 12 V.

    2. Disconnect the negative terminal cable from the battery.

    3. Disconnect the fuel hose from the fuel filter assembly.

    4. A01BCVHE01

      Install SST (pressure gauge) using SSTs and a fuel tube connector as shown in the illustration.

      SST
      09268-41048   ( 09268-41120, 90467-13001, 95336-08070, 09268-41500 )

    5. Wipe off any splattered gasoline.

    6. Reconnect the negative terminal cable to the battery.

    7. Connect the intelligent tester to the DLC3 (See step 1 in check fuel pump operation).

    8. Measure the fuel pressure.

      Fuel pressure
      281 to 287 kPa (2.87 to 2.93 kgf/cm2, 40.8 to 41.7 psi)

      If pressure is high, replace the fuel pressure regulator.

      If pressure is low, check the fuel hoses, fuel hose connection, fuel pump, fuel filter and fuel pressure regulator.

    9. Disconnect the intelligent tester from the DLC3.

    10. Stop the engine.

    11. Measure the fuel pressure at idle.

      Fuel pressure
      281 to 287 kPa (2.87 to 2.93 kgf/cm2, 40.8 to 41.7 psi)

      If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator.

    12. Stop the engine.

    13. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped.

      Fuel pressure
      147 kPa (1.5 kgf/cm2, 21 psi) or higher

      If pressure is not as specified, check the fuel pump, pressure regulator and/or injector.

    14. After checking fuel pressure, disconnect the negative terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing.

    15. Connect the fuel hose to the fuel filter assembly.

    16. Reconnect the negative terminal cable to the battery.

    17. Check for fuel leakage.

  15. CHECK FOR FUEL LEAKS


    1. When using the intelligent tester


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to the on position and intelligent tester main switch ON.

        Note

        Do not start the engine.

      3. Select the Active Test mode on the intelligent tester.

        Tech Tips

        Please refer to the intelligent tester operator's manual for further details.

    2. When not using the intelligent tester.


      1. A01BG6SE01

        Disconnect the fuel pump connector.

      2. Using a service wire, connect terminals FP and +B of the relay block.

        Note

        Pay attention to the terminal connecting position to avoid a malfunction.

      3. Turn the ignition switch to the ON position, and check that the fuel pump operates.

        Note

        Do not start the engine.

    3. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.

    4. Check that the pulsation damper screw rises up when the fuel pump operates.

      If operation is not as specified, check the following parts:


      • Fusible link

      • Fuel pump

      • Wiring connections

      • ECM

      • Fuses

    5. Turn the ignition switch off.

    6. Disconnect the intelligent tester from the DLC3.