FUEL SUB TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B001ZUBE05

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

      Text in Illustration
      *a Tank Side Mark
      *b Hose Side Mark

      Tech Tips


      • Align the fuel sub tank side mark with the hose side mark when installing the hose.

      • B001X49E07

        Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

      Text in Illustration
      *a Stopper

  2. INSTALL NO. 3 FUEL HOSE


    1. B001W06E05

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

      Text in Illustration
      *a Tank Side Mark
      *b Hose Side Mark

      Tech Tips


      • Align the fuel sub tank side mark with the hose side mark when installing the hose.

      • B001X49E07

        Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

      Text in Illustration
      *a Stopper

  3. INSTALL FUEL TANK BREATHER HOSE


    1. Install the breather hose to the fuel sub tank.

  4. INSTALL FUEL AND EVAPORATION VENT TUBE SUB-ASSEMBLY


    1. 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. except G.C.C. Countries:

      Install the 2 fuel tank evaporation vent tubes.

    2. for G.C.C. Countries:

      Install the fuel tank evaporation vent tube.

  6. INSTALL FUEL HOSE


    1. Install the fuel hose.

  7. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. 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. 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 an engine lifter and raise the fuel sub tank.

    2. 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. Connect the hose to the filler pipe.

  11. CONNECT NO. 3 FUEL HOSE


    1. Connect the fuel hose to the filler pipe.

  12. CONNECT FUEL TANK BREATHER HOSE


    1. Connect the breather hose to the filler pipe.

  13. CONNECT FUEL HOSE


    1. Connect the fuel hose.

  14. CONNECT FUEL TANK EVAPORATION VENT TUBE SUB-ASSEMBLY


    1. except G.C.C. Countries:

      Connect the 2 fuel tank evaporation vent tubes.

    2. for G.C.C. Countries:

      Connect the fuel tank evaporation vent tube.

  15. INSTALL FUEL TANK CAP ASSEMBLY

  16. INSTALL NO. 1 SPARE WHEEL STOPPER


    1. 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 with the 6 bolts labeled C.

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

    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 }
      B001Z1OE01

  18. INSTALL TAILPIPE ASSEMBLY

    Click here

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  20. INSPECT FOR FUEL LEAK

    Click here

  21. INSPECT FOR EXHAUST GAS LEAK

  22. INSTALL SPARE TIRE