FUEL TANK INSTALLATION


  1. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. A015YNP

      Install a new No. 1 fuel tank protector to the fuel tank assembly.

  2. INSTALL FUEL TANK CUSHION


    1. A015YT7

      Install 11 new fuel tank cushions shown in the illustration.

  3. INSTALL FUEL TANK VENT HOSE


    1. A015ZXE

      Install the fuel tank vent hose with the clip.

  4. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. A016109

      Install the fuel tank to filler pipe hose to the fuel tank assembly with the clamp.

    2. Tighten the hose clamp bolt.

  5. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. A015Z1OE03

      Install the 2 tank bracket retainer sub-assemblies.

    2. A0160NH

      Install the edge protector with the 2 clamps.

    3. A015YOV

      Install a fuel tank main tube and fuel tank return vent tube with the clamp.

  6. INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY


    1. Install a new gasket to the No. 1 fuel tank breather tube sub-assembly.

    2. A0162GS

      Install the No. 1 fuel tank breather tube sub-assembly with the 4 screws.

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

  7. INSTALL FUEL TANK ASSEMBLY


    1. Set the fuel tank assembly onto the transmission jack.

    2. A0160QQ

      Raise the transmission jack so that the No. 1 fuel tank breather tube sub-assembly can be connected. Connect the hose.

      Note

      Slowly raise the jack as to not drop the fuel tank assembly.

    3. A0161EM

      Install the fuel tank assembly with the fuel tank bands and 4 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  8. CONNECT FUEL TANK VENT HOSE


    1. A0161XF

      Connect the fuel tank vent hose with the clamp.

  9. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A015YHU

      Connect the fuel tank to filler pipe hose with the clamp.

  10. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A0161CKE01

      Connect the fuel tank main tube (RH side).


      1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.

        Note


        • Check for damage or foreign matter on the connected part.

        • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

    2. A0163HBE02

      Connect the fuel tank return vent tube.


      1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.

        Note


        • Check for damage or foreign matter on the connected part.

        • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

    3. A015ZVYE02

      Connect the fuel tank main tube (LH side).


      1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.

        Note


        • Check for damage or foreign matter on the connected part.

        • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

  11. CONNECT PARKING BRAKE CABLE ASSEMBLY


    1. A0160ZW

      Install the bolt, loosen the grommet then install No. 3 fuel tank protector.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Install the bolt, loosen the grommet then install No. 4 fuel tank protector.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    3. A0160G8E01

      Connect the 4 clamps.

    4. Connect the 2 parking brake cable assemblies with the 4 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf, for bolt A }
      19 N*m  { 194 kgf*cm, 14 ft.*lbf, for bolt B }

  12. INSTALL REAR SUSPENSION REAR LOWER MEMBER BRACE LH


    1. A015ZSS

      Install the rear suspension rear lower member brace LH with the 4 bolts.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  13. INSTALL REAR SUSPENSION REAR LOWER MEMBER BRACE RH

    Tech Tips

    Perform the same procedure as the LH side.

  14. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Tech Tips

    Click here.

  15. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Tech Tips

    Click here.

  16. INSTALL NO. 2 FLOOR UNDER COVER

  17. INSTALL NO. 1 FLOOR UNDER COVER

  18. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR


    1. A0163AZ

      Install the No. 2 differential support protector with the 2 nuts.

  19. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR

    Tech Tips

    Use the same procedure as for the No. 2 differential support protector.

  20. INSTALL FUEL SENDER GAUGE


    1. A015YWB

      Install the fuel sender gauge with the 5 bolts to the fuel tank.

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

      Note

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

    2. A015ZOG

      Connect the fuel sender gauge connector.

  21. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. Install a new fuel suction tube set gasket onto the fuel tank.

    2. A0162G3

      Connect the fuel tube with the clip.

    3. Set the fuel suction with pump and tube assembly to the fuel tank.

      Note


      • Make sure that the fuel sender gauge assembly arm does not bend.

      • Do not damage the fuel tube.

    4. A0161ZBE01

      Align the protrusion of the fuel suction with pump and gauge tube assembly and the cutout of the fuel tank vent tube set plate.

    5. While holding the fuel suction with pump and gauge tube assembly by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.

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

    6. Connect the fuel pump tubes.


      1. A015YTRE01

        Push the fuel tube joint in the plug of the fuel suction plate, and then install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips.

        Note


        • 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.

        • Be careful not to damage any clips. If a clip is damaged, replace it.

    7. Connect the fuel suction tube connector.

  22. ADD FUEL

  23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  24. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


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

      5. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing in the fuel tank can be heard. If no sounds can be heard, check the instrument panel junction block, fuel pump, ECM and wiring connectors.

    2. Inspect for fuel leaks.


      1. Check that there are no fuel leaks from the fuel system after performing any maintenance. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the engine switch off.

    4. Disconnect the intelligent tester from the DLC3.

  25. INSPECT FOR EXHAUST GAS LEAK

  26. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. A016254

      Install the service hole cover with new butyl tape.

  27. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER


    1. A016306

      Install the No. 2 rear floor service hole cover with new butyl tape.

  28. INSTALL NO. 3 ROOM PARTITION PAD


    1. A015ZGAE01

      Install the No. 3 room partition pad with the clip.

  29. INSTALL REAR SEAT CUSHION ASSEMBLY


    1. A0162ZH

      Engage the 2 rear hooks of the seat cushion to the child restraint seat anchor bracket.

    2. Engage the 2 front hooks of the seat cushion to the vehicle body.

    3. Confirm that the seat cushion is firmly installed.

      Note

      When installing the seat cushion, make sure the seat belt buckle is not under the seat cushion.