FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A004ZCS

      Install 2 new fuel tank cover vent case sub-assemblies as shown in the illustration.

  2. INSTALL NO. 1 FUEL TANK CUSHION


    1. A004YE8E02
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion

      Install 3 new No. 1 fuel tank cushions as shown in the illustration.

  3. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Install the hose clamp and the No. 1 charcoal canister outlet hose to the fuel tank.

  4. INSTALL FUEL TANK ASSEMBLY


    1. Support the fuel tank using an engine lifter.

    2. Raise the engine lifter, then 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. Tighten the 4 set bolts of the 2 fuel tank bands.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

    4. Connect the parking brake cable assembly with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Align the fuel tube connector with the fuel pipe, push the fuel tube connector in until the retainer makes a "click" sound, then lock the fuel tube connector cover of the fuel tube connector.

      A004Y6UE03
      Text in Illustration
      *1 Fuel Tube Connector Cover
      *2 Retainer
      *3 Nylon Tube
      *4 Fuel Tube Connector
      *5 Fuel Pipe
      *6 O-ring
      *a Push

      Note


      • Check that there are no scratches or foreign matter around the connected parts of the fuel tube connector and fuel pipe before performing this work.

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

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


    1. A004YU1E06
      Text in Illustration
      *1 Rubber Hose
      *2 O-ring
      *3 Fuel Pipe
      *4 Retainer
      *a Push

      Push in the tube connector to the fuel pipe and install the retainer.

      Note


      • Check if there is any damage or foreign matter on the connected parts of the fuel pipe.

      • After connecting the fuel tube connector and pipe, check if they are securely connected by pulling on them.

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A004XKCE01
      Text in Illustration
      *a Upper Side
      *b 120°

      Connect the fuel tank to filler pipe hose to the fuel tank as shown in the illustration, then fit the hose with the clamp.

  8. CONNECT FUEL TANK BREATHER TUBE


    1. Connect the fuel tank breather tube to the fuel tank.

    2. Connect the No. 1 charcoal canister outlet hose.

      Note

      After connecting the breather tube and No. 1 charcoal canister outlet hose, check that the evaporation vent tube clamp is securely connected to the fuel tank.

  9. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Install the No. 1 fuel tank protector with the 2 bolts and nut.

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

  10. INSTALL REAR FLOOR SIDE MEMBER COVER LH


    1. A004Z2R

      Install the rear floor side member cover LH with the 2 clips.

    2. Install the 2 bolts and nut.

  11. INSTALL TAIL EXHAUST PIPE ASSEMBLY

    Click here

  12. ADD FUEL

  13. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  14. INSPECT FOR EXHAUST GAS LEAK