FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. B001XHQE01

      Install the heat insulator with the 4 clips.

    2. Install the fuel tube clamp to the heat insulator.

  2. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B001VYOE01
      *1 Fuel Tank Side Mark
      *2 Hose Side Mark

      Install the fuel tank to filler pipe hose to the fuel tank as shown in the illustration.

  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE (for Single Tank Type)


    1. B001YQT
      B001X5OE03

      Install the 2 fuel tank tubes with the 2 tube joint clips.

      Note


      • Check that there are no scratches or foreign objects 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.

    2. B001W0C

      Install the 2 fuel tubes to the fuel tank.

  5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY, FUEL TANK RETURN TUBE AND NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B001XE8
      B001X5OE03

      Install the 3 fuel tank tubes with the 3 tube joint clips.

      Note


      • Check that there are no scratches or foreign objects 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.

    2. B001WTS

      Install the 3 fuel tubes to the fuel tank.

  6. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank on a transmission jack.

    2. Raise the transmission jack.

    3. B001Z78

      Install the 2 fuel tank bands with the 2 pins and 2 clips.

    4. Connect the 2 fuel tank bands with the 2 bolts.

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

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE (for Single Tank Type)


    1. B001YBSE01
      *1 0 to 0.3 mm
      *2 Hose Side Mark
      *3 Pipe Side Mark

      Connect the hose to the fuel tank filler pipe as shown in the illustration.

  8. CONNECT FUEL TANK TO FILLER PIPE HOSE (for Double Tank Type)


    1. B001YEQE01
      *1 0 to 0.3 mm
      *2 Hose Side Mark
      *3 Pipe Side Mark

      Connect the hose to the fuel tank filler pipe as shown in the illustration.

  9. CONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. B001ZNLE01
      *1 Retainer

      Connect the fuel tank breather tube to the filler pipe and push the retainer.

      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.

    2. Attach the fuel tube clamp.

  10. CONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. B001VXIE01
      *1 Retainer

      Connect the fuel tank breather tube to the filler pipe and push the retainer.

      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.

    2. Attach the fuel tube clamp.

  11. CONNECT NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. B001YJWE01
      *1 Fuel Tube
      *2 Grommet

      Connect the No. 2 fuel tank breather tube to the body.

      Tech Tips

      Make sure the No. 2 fuel tank breather tube is securely inserted into the grommet.

    2. Attach the fuel tube clamp.

  12. CONNECT NO. 2 FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. B001X70E01

      Connect the fuel tank breather tube and push the retainer.

      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.

    2. Attach the fuel tube clamp.

  13. CONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B001XRBE01

      Connect the No. 2 fuel main tube and push the retainer.

      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.

    2. Attach the fuel tube clamp.

  14. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B001XCX

      Connect the fuel tank main tube.

    2. Attach the fuel tube clamp.

  15. CONNECT FUEL TANK RETURN TUBE


    1. B001WQ5E01

      Connect both ends of the fuel tank return tube and push the retainer.

      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.

    2. Attach the fuel tube clamp.

  16. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. B001VWF

      Install the tank protector with the 5 bolts.

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

  17. INSTALL FUEL TANK CAP ASSEMBLY

  18. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. B00200VE03
      *1 for Single Tank Type:
      *2 for Double Tank Type:

      Connect the fuel pump and fuel sender gauge connector.

    2. B001VV2

      Install the service hole cover with new butyl tape.

    3. B001WTX

      w/ Rear Air Conditioning System:

      Install the air duct and 2 screws.

  19. INSTALL FRONT FLOOR CARPET ASSEMBLY

  20. INSTALL REAR AIR DUCT GUIDE (w/ Rear Air Conditioning System)

    Click here

  21. INSTALL AIR DUCT PLUG (w/ Rear Air Conditioning System)

    Click here

  22. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH


    1. w/ Sliding Roof:

      Install the front quarter trim panel assembly LH Click here.

    2. w/o Sliding Roof:

      Install the front quarter trim panel assembly LH Click here.

  23. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH


    1. w/ Sliding Roof:

      Install the front quarter trim panel assembly RH Click here.

    2. w/o Sliding Roof:

      Install the front quarter trim panel assembly RH Click here.

  24. INSTALL REAR SEAT COVER CAP (w/ Rear No. 2 Seat, except Face to Face Seat Type)

    Click here

  25. INSTALL REAR FLOOR MAT REAR SUPPORT PLATE

    Click here

  26. INSTALL REAR DOOR SCUFF PLATE LH

    Click here

  27. INSTALL REAR DOOR SCUFF PLATE RH

    Click here

  28. INSTALL REAR STEP COVER

    Click here

  29. INSTALL REAR NO. 2 SEAT PROTECTOR

    Click here

  30. INSTALL REAR NO. 1 SEAT PROTECTOR

    Click here

  31. INSTALL REAR NO. 2 SEAT ASSEMBLY


    1. for Face to Face Seat Type:

      Install the rear No. 2 seat assembly Click here.

    2. except Face to Face Seat Type:

      Install the rear No. 2 seat assembly Click here.

  32. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type 40 Side)


    1. Install the rear No. 1 seat assembly RH Click here.

  33. INSTALL REAR NO. 1 SEAT ASSEMBLY LH (for 60/40 Split Seat Type 60 Side)


    1. Install the rear No. 1 seat assembly LH Click here.

  34. BLEED AIR FROM FUEL SYSTEM

    Click here

  35. 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.

  36. CHECK SRS WARNING LIGHT


    1. Check the SRS warning light Click here.

  37. ADD FUEL

  38. INSPECT FOR FUEL LEAK

    Click here