FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. Attach the 2 clamps and install the fuel tank return tube sub-assembly.

  2. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. w/o Combustion Type Power Heater:

      Attach the 2 clamps and install the fuel tank main tube sub-assembly.

    2. w/ Combustion Type Power Heater:

      Attach the 2 clamps and install the fuel tank main tube sub-assembly and No. 2 fuel tank main tube sub-assembly.

  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 an engine lifter, support the fuel tank assembly.

    2. Raise the engine lifter and install the fuel tank assembly to the vehicle.

      Note


      • Do not drop the fuel tank assembly.

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

    3. Install the 2 fuel tank bands with the 4 bolts.

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

    4. w/ Combustion Type Power Heater:

      Connect the No. 2 fuel tank main tube sub-assembly and slide the clamp to secure it.

    5. Connect the fuel tank main tube sub-assembly Click here.

    6. Connect the fuel tank return tube sub-assembly Click here.

    7. Connect the parking brake cable with the 2 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    8. A004QWUE02
      Text in Illustration
      *a 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 assembly.

  5. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A004RUWE01
      Text in Illustration
      *a Top

      Connect the fuel tank to filler pipe hose to the fuel tank assembly 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. Install the rear floor side member cover RH with the clip and 2 grommets.

  7. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Install the No. 1 fuel tank 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 SUCTION WITH PUMP AND GAUGE TUBE 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. CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (w/ Combustion Type Power Heater)

    Click here

  16. INSTALL REAR FLOOR SERVICE HOLE COVER

    Click here

  17. INSPECT FOR FUEL LEAK

    Click here

  18. INSPECT FOR EXHAUST GAS LEAK

    Click here

  19. INSTALL REAR SEAT CUSHION ASSEMBLY