FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK CUSHION


    1. A001C62

      Install the 5 tank cushions and fuel tank protector.

    2. A001D49

      Install the 6 tank cushions.

  2. INSTALL NO. 2 FUEL TANK PROTECTOR

    A001AMY

    1. Install the clamp to the fuel tank.

    2. Install the bolt and clip and fuel tank protector to the fuel tank.

  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0019IU

      Install the fuel hose clamp.

    2. A0019NO

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

  4. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. A001CA2

      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 }

  5. 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. A001ETF

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

      Note


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

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

    3. A001EB7E05
      *1 Protrusion
      *2 Cutout

      Install the lower fuel tank protector and fuel tank vent tube 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 pump and gauge.

  6. INSTALL FUEL TANK ASSEMBLY


    1. Set the fuel tank on a engine lifter.

    2. Raise the engine lifter so that the fuel tank breather tube can be connected.

      Tech Tips

      Raise the engine lifter slowly.

    3. A00197C

      Connect the No. 1 fuel tank breather tube.

    4. A001F3WE01
      *1 Push
      *2 Retainer

      Connect the fuel tank to canister tube.

      Tech Tips

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

      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.

    5. A001CSK

      Slowly raise the engine lifter, and install the 2 fuel tank bands with the 4 bolts.

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

      Note


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

      • Make sure that the fuel tank is free from the fuel tank vent hose.

    6. A001EGM

      Connect the filler pipe hose to the fuel tank.

    7. Tighten the clamp.

    8. A001FTFE01

      Connect the fuel tank main tube.

      Tech Tips

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

      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.

    9. A001FTFE01

      Connect the fuel tank return vent tube.

      Tech Tips

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

      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.

  7. INSTALL FUEL TANK PROTECTOR SIDE BRACKET


    1. A001DPT

      Install the protector bracket with the 2 bolts.

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

  8. INSTALL FUEL TANK FILLER PIPE PROTECTOR


    1. A0019SM

      Attach the 2 clips and protector.

    2. Install the 2 nuts.

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

  9. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  10. INSTALL REAR FLOOR SERVICE HOLE COVER

    A001EIF

    1. Connect the fuel sender gauge connector.

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

  11. INSTALL FUEL TANK MAIN AND RETURN TUBE

    A001CEQ

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

      Note

      A001DWPE12

      • 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.

  12. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER

    A001BO6

    1. Connect the connector.

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

  13. INSTALL COWL TOP VENTILATOR LOUVER

    Click here

  14. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  15. INSPECT FOR FUEL LEAK

    Click here

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


  17. INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Type)

    Click here