FUEL SUB TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B001ZUBE06
      *1 Tank Side Mark
      *2 Hose Side Mark

      Install the hose to the fuel sub tank as shown in the illustration.

  2. INSTALL NO. 3 FUEL HOSE


    1. B001W06E07
      *1 Tank Side Mark
      *2 Hose Side Mark

      Install the fuel hose to the fuel sub tank as shown in the illustration.

  3. INSTALL FUEL TANK BREATHER HOSE


    1. B001ZX8

      Install the breather hose to the fuel sub tank.

  4. INSTALL FUEL AND EVAPORATION VENT TUBE SUB-ASSEMBLY


    1. B001YXR

      Install a new gasket to the fuel and evaporation vent tube.

    2. Install the fuel and evaporation vent tube with the 6 bolts.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  5. INSTALL FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY


    1. B001Z4S

      Install the 2 fuel tank evaporation vent tubes.

  6. INSTALL FUEL HOSE


    1. B001ZNS

      Install the 3 fuel hoses.

  7. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. B001WXQ

      Install a new gasket to the sender gauge.

      Note

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

    2. Install the sender gauge with the 5 screws.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

  8. INSTALL FLOOR NO. 3 WIRE


    1. B001XTA

      Attach the wire harness clamp to the fuel sub tank.

    2. Connect the sender gauge connector.

  9. INSTALL FUEL SUB TANK SUB-ASSEMBLY


    1. Set the fuel sub tank on a transmission jack and raise the fuel sub tank.

      Note

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

    2. B001X78

      Connect the 2 fuel tank bands with the 2 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    3. Connect the floor No. 3 wire connector.

    4. Attach the 3 wire harness clamps.

  10. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B001WMQ

      Connect the hose to the filler pipe.

  11. CONNECT NO. 3 FUEL HOSE


    1. B001YDA

      Connect the fuel hose to the filler pipe.

  12. CONNECT FUEL TANK BREATHER HOSE


    1. B001ZXH

      Connect the breather hose to the filler pipe.

  13. CONNECT FUEL HOSE


    1. B001XOH

      Connect the 3 fuel hoses.

  14. CONNECT FUEL TANK EVAPORATION VENT TUBE


    1. B001YK4

      Connect the 2 fuel evaporation vent tubes.

  15. INSTALL FUEL TANK CAP ASSEMBLY

  16. INSTALL NO. 1 SPARE WHEEL STOPPER


    1. B001WCF

      Install the spare wheel stopper with the 2 bolts.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  17. INSTALL SPARE WHEEL CARRIER CROSSMEMBER AND SPARE WHEEL CARRIER BRACKET


    1. Install the spare wheel carrier crossmember and 2 brackets to the vehicle body with the 6 bolts labeled C.

      Torque:
      for bolt C
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      B001Z1OE01

    2. Temporarily install the bolt labeled A, and then tighten the bolt labeled A and bolts labeled B.

      Torque:
      for bolt A
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for bolt B
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  18. INSTALL TAILPIPE ASSEMBLY

    Click here

  19. BLEED AIR FROM FUEL SYSTEM

    Click here

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.

  21. INSPECT FOR FUEL LEAK

    Click here

  22. INSPECT FOR EXHAUST GAS LEAK

  23. INSTALL SPARE TIRE