FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A004SK8

      Attach the 2 clamps and install the fuel tank main tube.

  2. INSTALL FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A004OJK

      Attach the 2 clamps and install the fuel tank return tube.

  3. INSTALL FUEL TANK CUSHION


    1. A004SEXE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

      Install a new No. 1 fuel tank cushion and 3 new No. 2 fuel tank cushions at the locations shown in the illustration.

  4. INSTALL FUEL TANK ASSEMBLY


    1. Using a transmission jack, support the fuel tank.

    2. Raise the transmission jack and install the fuel tank to the vehicle.

      Note


      • Do not drop the fuel tank.

      • When installing the fuel tank, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

    3. A004NA0

      Install the 2 fuel tank bands with the 4 bolts.

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

    4. Connect the fuel tank main tube.


      1. Align the fuel tube connector with the pipe, push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, and then push the retainer up until the claws lock.

        A004TT0E01

        Note


        • Check that there are no scratches or foreign objects around the connecting part of the fuel tube connector and pipe before starting this step.

        • After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector.

    5. Connect the fuel tank return tube.


      1. Align the fuel tube connector with the pipe, push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank return tube to the pipe, and then push the retainer up until the claws lock.

        A004SQUE01

        Note


        • Check that there are no scratches or foreign objects around the connecting part of the fuel tube connector and pipe before starting this step.

        • After connecting the fuel tank return tube, check that the fuel tank return tube is securely connected by pulling on the fuel tube connector.

    6. A004R7D

      Connect the parking brake cable with the 2 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    7. A004QWUE01
      *1 Top

      Connect the breather hose to the fuel tank filler pipe and tighten the hose clamp bolt so that the clamp is as shown in the illustration.

      Note

      After connecting the breather hose, check that the evaporation vent tube clamp is securely connected to the fuel tank.

  5. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A004PMGE01
      *1 Top

      Connect the filler pipe hose to the fuel tank and tighten the hose clamp bolt so that the clamp is as shown in the illustration.

      Note

      Be sure to tighten the hose clamp so that it is at the correct angle.

  6. INSTALL REAR FLOOR SIDE MEMBER COVER RH


    1. A004RNO

      Install the rear floor side member cover RH with the clip and 2 grommets.

  7. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. A004R3U

      Install the protector with the 3 bolts.

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

  8. INSTALL TAILPIPE ASSEMBLY

    Click here

  9. ADD FUEL

  10. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY

    Click here

  11. INSTALL FUEL PUMP GAUGE RETAINER

    Click here

  12. INSTALL TANK SUCTION TUBE SUPPORT

    Click here

  13. CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY

    Click here

  14. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Click here

  15. INSTALL REAR FLOOR SERVICE HOLE COVER

    Click here

  16. BLEED AIR FROM FUEL SYSTEM

    Click here

  17. INSPECT FOR FUEL LEAK

    Click here

  18. INSPECT FOR EXHAUST GAS LEAK

    Click here

  19. INSTALL REAR SEAT CUSHION ASSEMBLY


    1. for Sedan:

      Install the rear seat cushion assembly Click here.

    2. for Wagon:

      Install the rear seat cushion assembly Click here.