FUEL TANK INSTALLATION


  1. INSTALL FUEL TANK CUSHION


    1. A01GHXY

      Install the 5 tank cushions and fuel tank protector.

    2. A01GING

      Install the 6 tank cushions.

  2. INSTALL NO. 2 FUEL TANK PROTECTOR

    A01GJI3

    1. Install the clamp to the fuel tank.

    2. Install the bolt and clip and fuel tank protector to the fuel tank.

  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01GK4R

      Install the fuel hose clamp.

    2. A01GMD5

      Install the fuel tank main tube to the fuel tank with the 6 clamps.

  4. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. A01GHMO

      Install a new gasket and sender gauge to the fuel tank with the 5 screws.

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

  5. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.

    2. A01GMKI

      Connect the fuel hose, and set the fuel suction with pump and gauge.

      Note


      • Be careful not to bend the arm of the fuel sender gauge.

      • When connecting the fuel hose, do not forcibly pull the hose.

    3. A01GHX2E01

      Install the set plate with the 8 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Tech Tips

      Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.

  6. INSTALL FUEL TANK ASSEMBLY


    1. Set the fuel tank on a engine lifter.

    2. Raise the engine lifter so that the fuel tank breather tube can be connected.

      Tech Tips

      Raise the engine lifter slowly.

    3. A01GM8O

      Connect the No. 1 fuel tank breather tube sub-assembly .

    4. A01GJKRE02

      Connect the fuel tank to canister tube sub-assembly.

      Tech Tips

      Push the parts together firmly until a "click" sound is heard.

      Note


      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

    5. A01GK0N

      Slowly raise the engine lifter, and install the 2 fuel tank bands with the 4 bolts.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note


      • Do not allow the fuel tank to contact the vehicle, especially the differential.

      • Make sure that the fuel tank is free from the fuel tank vent hose sub-assembly.

    6. A01GKNC

      Connect the filler pipe hose to the fuel tank.

    7. Tighten the clamp.

    8. A01GMRYE01

      Connect the fuel main tube.

      Tech Tips

      Push the parts together firmly until a "click" sound is heard.

      Note


      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

    9. A01GMRYE01

      Connect the fuel return tube.

      Tech Tips

      Push the parts together firmly until a "click" sound is heard.

      Note


      • Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

      • After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

  7. INSTALL FUEL TANK PROTECTOR SIDE BRACKET


    1. Install the fuel tank protector side bracket with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  8. INSTALL FUEL TANK FILLER PIPE PROTECTOR


    1. Attach the 2 clips and fuel tank filler pipe protector.

    2. Install the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  9. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  10. INSTALL REAR FLOOR SERVICE HOLE COVER

    A01GK8R

    1. Connect the fuel sender gauge connector.

    2. Install the service hole cover with new butyl tape.

  11. INSTALL FUEL TANK MAIN AND RETURN TUBE

    A01GKFF

    1. Install the fuel main tube and fuel return tube with the 2 tube joint clips.

      Note


      • A01GJR8E03

      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • Check that the tube joint clips are on the collars of the fuel tube joints.

      • After installing the tube joint clips, check that the fuel tube joints have not been pulled off.

  12. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. Install the service hole cover with new butyl tape.

  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  14. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. A01GM4S

      Install the 6 clips and cowl top ventilator louver RH.

      Note

      If the cowl top ventilator louver RH is not properly installed, water may leak into the engine room and cause malfunctions. Therefore, make sure the cowl top ventilator louver RH is installed properly.

  15. CHECK FOR FUEL LEAKS


    1. Connect the intelligent tester to the DLC3.

    2. Turn the engine switch on (IG).

      Note

      Do not start the engine.

    3. Turn the intelligent tester on.

    4. Select the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

    5. Check the fuel pump operation.


      1. Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard.

        If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.

    6. Check for fuel leaks.


      1. Check that there are no fuel leaks anywhere on the system after performing maintenance.

        If there is a fuel leak, repair or replace parts as necessary.

  16. INSTALL REAR NO. 1 AND NO. 2 SEAT ADJUSTER ASSEMBLY


  17. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Type)

    Click here