FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. Install the No. 1 fuel tank heat insulator with the 4 clips.

    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.

  2. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B001VYOE04

      Install the fuel tank to filler pipe hose to the fuel tank sub-assembly as shown in the illustration and tighten the hose clamp.

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

      Tech Tips


      • Align the fuel 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 SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

  4. INSTALL FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B001YT3E02
      Text in Illustration
      *1 Fuel Tube Joint
      *2 O-Ring
      *3 Tube Joint Clip
      *a CORRECT
      *b INCORRECT

      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. for G.C.C. Countries:


      1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

      2. Attach the clamp and install the fuel tank return tube sub-assembly.

      3. Attach the clamp and install the fuel tank main tube sub-assembly.

    3. except G.C.C. Countries:


      1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

      2. Attach the clamp and install the fuel tank return tube sub-assembly.

      3. Attach the clamp and install the fuel tank main tube sub-assembly.

  5. CONNECT FUEL HOSE


    1. for G.C.C. Countries:

      Install the fuel hose to the fuel suction tube sub-assembly, and slide the clip to secure the hose.

  6. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank sub-assembly on an engine lifter and raise the fuel tank sub-assembly.

      Note

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

    2. Raise the engine lifter.

    3. Install the 2 fuel tank band sub-assemblies with the 2 pins and 2 clips.

    4. Connect the 2 fuel tank band sub-assemblies with the 2 bolts.

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

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B001YEQE04

      Connect the fuel tank to filler pipe hose to the fuel tank to filler pipe sub-assembly as shown in the illustration and tighten the hose clamp.

      Text in Illustration
      *a 0 to 0.3 mm (0 to 0.0118 in.)
      *b Fuel Tank to Filler Pipe Hose Side Mark
      *c Fuel Tank Inlet Pipe Side Mark

      Tech Tips


      • Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.

      • 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

  8. CONNECT FUEL TANK BREATHER TUBE


    1. B001XOYE01
      Text in Illustration
      *1 Retainer
      B001XPG Push

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

      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.

      Tech Tips

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

    2. Attach the fuel tube clamp.

  9. CONNECT NO. 2 FUEL TANK BREATHER TUBE


    1. B001VX4E01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      B001XPG Push

      except G.C.C. Countries:


      1. Connect the No. 2 fuel tank breather tube and push the retainer.

        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.

        Tech Tips

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

      2. Attach the fuel tube clamp.

  10. CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

    B001WFVE03
    Text in Illustration
    *1 Retainer *2 Connector
    *3 O-Ring *4 Pipe
    *5 Nylon Tube - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    B001XPG Push - -

    1. Connect the No. 2 fuel tank main tube sub-assembly and push the retainer.

      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.

      Tech Tips

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

    2. Attach the fuel tube clamp.

  11. CONNECT FUEL HOSE


    1. for G.C.C. Countries:


      1. Connect the fuel hose to the pipe, and slide the clip to secure the hose.

      2. Attach the fuel tube clamp.

  12. CONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY


    1. B001YREE01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      B001XPG Push

      except G.C.C. Countries:


      1. Connect the No. 1 fuel emission tube sub-assembly and push the retainer.

        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.

        Tech Tips

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

      2. Attach the fuel tube clamp.

    2. B001WRNE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      B001XPG Push

      for G.C.C. Countries:


      1. Connect the No. 1 fuel emission tube sub-assembly and push the retainer.

        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.

        Tech Tips

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

      2. Attach the fuel tube clamp.

  13. CONNECT FUEL TANK RETURN TUBE

    B001VQ7E01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    B001XPG Push - -

    1. Connect the fuel tank return tube and push the retainer.

      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.

      Tech Tips

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

    2. Attach the fuel tube clamp.

  14. CONNECT NO. 2 FUEL TANK BREATHER HOSE


    1. for G.C.C. Countries:


      1. Connect the No. 2 fuel tank breather hose to the pipe, and slide the clip to secure the hose.

      2. Attach the fuel pipe clamp.

  15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    B001YWNE01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    B001XPG Push - -

    1. Connect the fuel tank main tube sub-assembly and push the retainer.

      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.

      Tech Tips

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

    2. Attach the fuel tube clamp.

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


    1. Install the No. 1 fuel tank protector sub-assembly 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. Connect the fuel pump and fuel sender gauge connector.

    2. Install the rear floor No. 2 service hole cover with new butyl tape.

    3. Install the air duct and 2 screws.

  19. INSTALL FRONT FLOOR CARPET ASSEMBLY

  20. 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.

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

    Click here

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

    Click here

  23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  24. ADD FUEL

  25. INSPECT FOR FUEL LEAK

    Click here