FUEL TANK INSTALLATION


  1. INSTALL FUEL HOSE GROMMET


    1. Install the fuel hose grommet to the fuel tank assembly.

  2. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. Apply a light coat of gasoline or grease to a new fuel suction tube set gasket and install the fuel suction tube set gasket to the fuel tank assembly.

    2. A003ER3E01
      Text in Illustration
      *1 Fuel Suction Tube Set Gasket
      *a Protrusion
      *b Groove

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

      Note

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

    3. Install the fuel tank vent tube set plate with the 8 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    4. Connect the fuel tank wire connector.

  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Push the fuel tank main tube sub-assembly into the plug of the fuel suction with pump and gauge tube assembly, and then install the tube joint clip.

      Note

      A003DYDE13

      • Check that there are no scratches or foreign matter on the connecting parts.

      • Check that the fuel tube joints are 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 cannot be pulled off.

      Text in Illustration
      *1 Fuel Tube Joint
      *2 Fuel Tube
      *3 O-Ring
      *4 Tube Joint Clip
      *a CORRECT
      *b INCORRECT
  4. INSTALL FUEL TANK RETURN TUBE


    1. Push the fuel tank return tube into the plug of the fuel suction with pump and gauge tube assembly, and then install the tube joint clip.

      Note

      A003DYDE13

      • Check that there are no scratches or foreign matter on the connecting parts.

      • Check that the fuel tube joints are 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 cannot be pulled off.

      Text in Illustration
      *1 Fuel Tube Joint
      *2 Fuel Tube
      *3 O-Ring
      *4 Tube Joint Clip
      *a CORRECT
      *b INCORRECT
  5. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Connect the No. 1 fuel evaporation tube sub-assembly to the fuel suction with pump and gauge tube sub-assembly Click here.

  6. INSTALL FUEL TANK ASSEMBLY


    1. Set the fuel tank assembly onto an engine lifter.

    2. Operate the engine lifter, and then install the fuel tank assembly to the vehicle.

    3. Install the fuel tank assembly, No. 1 fuel tank band sub-assembly RH and No. 1 fuel tank band sub-assembly LH with the 6 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
    4. Connect the No. 3 parking brake cable assembly with the bolt.

      Torque:
      15 N*m  { 148 kgf*cm, 11 ft.*lbf }
  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. Connect the fuel tank to filler pipe hose to the fuel tank assembly, and tighten the hose clamp to secure the hose.

  8. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector to the fuel tank to filler pipe hose and attach the 2 claws.

  9. CONNECT FUEL TANK BREATHER HOSE


    1. Connect the fuel tank breather hose to the fuel tank assembly, and slide the clamp to secure the hose.

  10. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


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

  11. CONNECT FUEL TANK RETURN TUBE


    1. Connect the fuel tank return tube Click here.

  12. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Connect the No. 1 fuel evaporation tube sub-assembly to the fuel suction with pump and gauge tube assembly Click here.

  13. CONNECT FUEL TANK WIRE


    1. Connect the fuel tank wire connector.

  14. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  16. INSPECT FOR FUEL LEAK


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


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch to ON and turn the GTS 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 fuel 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 GTS from the DLC3.