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  { 153 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 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

    Tech Tips


    • Propeller shaft assembly for Super Long Wheelbase Click here.

    • Propeller shaft assembly for Long Wheelbase Click here.

  15. CHECK FOR FUEL LEAKS


    1. When using the intelligent tester


      1. Connect the intelligent tester to the DLC3.

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

        Note

        Do not start the engine.

      3. Select the Active Test mode on the intelligent tester.

        Tech Tips

        Please refer to the intelligent tester operator's manual for further details.

    2. When not using the intelligent tester.


      1. A003CJUE01

        Disconnect the fuel pump connector.

      2. Using a service wire, connect terminals FP and +B of the relay block.

        Note

        Pay attention to the terminal connecting position to avoid a malfunction.

      3. Turn the ignition switch to the ON position, and check that the fuel pump operates.

        Note

        Do not start the engine.

    3. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.

    4. Check that the pulsation damper screw rises up when the fuel pump operates.

      If operation is not as specified, check the following parts:


      • Fusible link

      • Fuel pump

      • Wiring connections

      • ECM

      • Fuses

    5. Turn the ignition switch off.

    6. Disconnect the intelligent tester from the DLC3.