FUEL TANK (for 3 Door) INSTALLATION


  1. INSTALL NO. 1 FUEL TANK CUSHION


    1. Install new 2 No. 1 fuel tank cushions to the fuel tank.

  2. INSTALL FUEL TUBE GROMMET


    1. Attach the clamp to install the fuel tube grommet.

  3. INSTALL FUEL TANK FILLER PIPE LOWER SUB-ASSEMBLY


    1. Install a new gasket and the fuel tank filler pipe lower with the 8 screws.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

  4. INSTALL FUEL TANK BREATHER HOSE


    1. Install the fuel tank breather hose to the fuel tank.

  5. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. Install the fuel tank to filler pipe hose to the fuel tank.

  6. INSTALL FUEL SENDER GAUGE ASSEMBLY


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

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

      Note

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

  7. INSTALL FUEL CUT OFF VALVE ASSEMBLY


    1. Install the fuel cut off valve to the fuel tank.

  8. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Install a new gasket and the No. 1 fuel evaporation tube with the 4 screws and attach the clamp.

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

  9. INSTALL FUEL SUCTION TUBE ASSEMBLY


    1. Install a new gasket and the fuel suction tube with the 7 screws and attach the 2 clamps.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  10. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank on a transmission jack and lift up the transmission jack.

    2. Install the 2 fuel tank bands with the 2 pins and 2 clips.

    3. Connect the 2 fuel tank bands with the 2 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  11. CONNECT FUEL TANK BREATHER HOSE


    1. Connect the fuel tank breather hose to the filler pipe.

  12. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. Connect the fuel tank to filler pipe hose to the filler pipe.

  13. CONNECT FUEL HOSE


    1. Connect the fuel evaporation hose and fuel hose.

  14. CONNECT FUEL MAIN TUBE


    1. Connect the fuel main tube Click here.

  15. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. Install the No. 1 fuel tank protector with the 5 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  16. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. Connect the fuel sender gauge connector and fuel pump connector.

    2. Install the rear floor service hole cover with the 3 screws.

  17. INSTALL REAR FLOOR MAT SUPPORT PLATE


    1. Attach the 6 claws to install the rear floor mat rear support plate.

    2. Install the 5 screws.

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  19. INSPECT FOR FUEL LEAK


    1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.


      1. Connect the intelligent tester to the DLC3.

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

        Note

        Do not start the engine.

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

      4. Check that there are no leaks from the fuel system.

        If there are fuel leaks, repair or replace parts as necessary.

      5. Turn the ignition switch off.

      6. Disconnect the intelligent tester from the DLC3.