FUEL TANK INSTALLATION

INSTALL FUEL TANK PROTECTOR LOWER CENTER
1. Install the fuel tank protector lower center with the 3 screws.
INSTALL FUEL TANK TO FILLER PIPE HOSE
1. Align the mark on the hose with the mark on the fuel tank, and install the fuel tank to filler pipe hose with the hose clamp bolt as shown in the illustration.
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Engage the 4 claws to install the fuel tank main tube and fuel emission tube.
INSTALL FUEL TANK ASSEMBLY
1. Install the fuel tank with 4 new bolts.
  
  Torque:
  
  14 N*m { 146 kgf*cm, 11 ft.*lbf }
2. Install the parking brake cable No.2 with the bolt.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
3. Install the parking brake cable No.3 with the bolt.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY
1. Install the fuel tank filler pipe with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Connect the fuel tank main tube.
  1. Push the fuel tube connector into the pipe until the connector makes a "click" sound.
    
    Note
    
    Before installing the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
    
    After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY
1. Connect the fuel tank return tube.
  1. Push the fuel tube connector into the pipe and push up the retainer so that the claws engage.
    
    Note
    
    Before installing the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
    
    After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
INSTALL EXHAUST FRONT PIPE ASSEMBLY
1. Install the exhaust front pipe assembly with a new clamp.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
2. Install the exhaust front pipe stay nut and exhaust pipe support No.4.
  
  Torque:
  
  7.7 N*m { 79 kgf*cm, 68 ft.*lbf }
3. Install a new clamp and bolt.
  
  Torque:
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }
  
  Note
  
  The clamp marks and stampings should be aligned.
INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Install a new gasket onto the fuel tank.
2. Set the fuel sender gauge assembly to the fuel tank.
  
  Note
  
  The sender gauge arm should not be bent.
INSTALL FUEL PUMP GAUGE RETAINER
1. Align the end of the threads of a new fuel pump gauge retainer with that of the fuel tank.
2. Using a socket wrench (6 mm), set SST to the fuel pump gauge retainer.
  
  SST
  
  09808-14020 ( 09808-01410, 09808-01420, 09808-01430 )
  
  Note
  
  Use only SST. Do not use any other tools such as a screwdriver.
  
  Tech Tips
  
  Fit the rib on the fuel pump gauge retainer into the cutout of the SST.
3. While holding the fuel pump assembly by hand, use the SST to tighten the fuel pump gauge retainer one and a half turns so that the mark on the retainer is within the indicated range in the illustration.
4. Connect the fuel tank main tube sub-assembly.
  1. Push the tube connector into the pipe until the tube connector makes a "click" sound.
    
    Note
    
    Before installing the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
    
    After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
5. Connect the fuel tank return tube sub-assembly.
  1. Push the tube connector into the pipe until the tube connector makes a "click" sound.
    
    Note
    
    Before installing the pipe, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.
    
    After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the connector.
2. Install the rear floor service hole cover with new butyl tape.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
INSTALL REAR SEAT CUSHION ASSEMBLY
- Separate seat type Click here
- Bench seat type Click here
ADD FUEL
CHECK FOR FUEL LEAKS
1. Check that there are no leaks from any part of the fuel system when the engine is stopped.
  
  If there is fuel leakage, repair or replace parts as necessary.
2. Start the engine and check that there are no leaks from any part of the fuel system.
  
  If there is fuel leakage, repair or replace parts as necessary.
3. Depress the accelerator pedal and rev up the 4000 rpm. After driving the vehicle, check for fuel leakage.
  
  If there is excessive fuel leakage, repair or replace parts as necessary.