FUEL TANK INSTALLATION


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


    1. Install the fuel tank protector to the fuel tank.

  2. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01GWXI

      Install the fuel tube 6 clamps.

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

  3. INSTALL FUEL TANK RETURN VENT TUBE


    1. A01GY5N

      Install the fuel tank return vent tube to the fuel tank.

  4. INSTALL FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY


    1. A01GX6VE02

      Install the canister tube to the fuel tank.

      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.

      Tech Tips

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

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


    1. A01H1EJ

      Install new gasket and the breather tube with the 4 screws.

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

  6. INSTALL FUEL TANK ASSEMBLY


    1. Set the fuel tank on a engine lifter and raise the fuel tank.

      Note

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

    2. A01GZ48

      Temporarily install the 2 fuel tank bands with the 4 bolts.

    3. Tighten the bolts in the front.

      Torque:
      39 N*m  { 408 kgf*cm, 30 ft.*lbf }
    4. A01GXIWE01

      Using SST, a torque wrench and union nut wrench, tighten the bolts in the rear.

      SST
      09961-00950
      Torque:
      without SST
      39 N*m  { 408 kgf*cm, 30 ft.*lbf }
      with SST
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 180 mm (7.09 in).

      • Make sure union nut wrench, SST and torque wrench are connected in a straight line. Fulcrum Length

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01H0A2

      Connect the filler pipe hose to the fuel tank.

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


    1. A01GYK3E01

      Connect the breather tube.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  9. CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY


    1. A01GW5TE01

      Connect the canister tube.

      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.

      Tech Tips

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

  10. CONNECT FUEL TANK RETURN VENT TUBE


    1. A01GZ52E01

      Connect the fuel tank return vent tube.

      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.

      Tech Tips

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

  11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01H23FE01

      Connect the fuel tank main tube LH.

      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.

      Tech Tips

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

    2. A01GX2TE01

      Connect the fuel tank main tube RH.

      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.

      Tech Tips

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

  12. INSTALL FUEL TANK PROTECTOR BRACKET SIDE


    1. A01GWRZ

      Install the protector with the 2 nuts.

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

  13. INSTALL FUEL TANK FILLER PIPE PROTECTOR


    1. A01GWTT

      Install the protector with the 2 clips and 2 nuts.

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

  14. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  15. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. A01H0IF

      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 }

  16. INSTALL REAR FLOOR SERVICE HOLE COVER

    A01GW94

    1. Connect the fuel sender gauge connector.

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

  17. 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. A01H0EM

      Connect the fuel hose, and install the fuel suction with pump and gauge tube to the fuel tank.

      Note


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

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

  18. INSTALL FUEL TANK VENT TUBE SET PLATE


    1. A01GXP6E01

      Install the No. 2 fuel tank protector and 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 with pump and gauge tube.

    2. A01GY9T

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

      Note

      A01H25BE03

      • 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.

  19. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER

    A01GWRK

    1. Connect the connector.

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

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


  21. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)

    Click here

  22. INSTALL SERVICE PLUG GRIP

    Click here

  23. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  24. INSTALL BATTERY SERVICE HOLE COVER LH


    1. A01GZIME02
      Text in Illustration
      *A for Standard
      *B for Ottoman

      Attach the battery service hole cover LH with the clip and fastening tape.

  25. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)


    1. A01GXQQ

      Attach the 2 clips to install the deck trim side board LH.

  26. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    A01GZ3P

  27. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    A01GWKI

  28. ADD FUEL

  29. INSPECT FOR FUEL LEAK


    1. Connect the intelligent tester to the DLC3.

    2. Turn the power switch on (IG).

      Note

      Do not start the engine.

    3. Turn the intelligent tester on.

    4. Select the following menus: Powertrain / Engine and ECT / 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.