FUEL TANK(for 5 Door) INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B001D1ZE04
      Text in Illustration
      *a Fuel Tank Side Mark
      *b Hose Side Mark

      Align the fuel tank side mark with the hose side mark.

    2. Install the fuel tank to filler pipe hose to the fuel tank sub-assembly, and tighten the clamp to secure the hose.

  2. INSTALL NO. 3 FUEL TANK PROTECTOR


    1. Install the No. 3 fuel tank protector and attach the 4 clamps.

    2. Install the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  3. INSTALL FUEL TANK VENT TUBE ASSEMBLY (for Single Tank Type)


    1. Apply a light coat of diesel fuel or grease to a new gasket and install the gasket to the fuel tank sub-assembly.

    2. B001CZ8E10
      Text in Illustration
      *a Protrusion
      *b Groove

      Align the protrusion of the fuel tank vent tube assembly with the groove of the fuel tank sub-assembly.

      Note

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

    3. Install the fuel tank vent tube assembly to the fuel tank sub-assembly.

    4. Put a new retainer on the fuel tank sub-assembly. While holding the fuel tank vent tube assembly, tighten the retainer one complete turn by hand.

      Tech Tips

      Make sure the start marks on the retainer and fuel tank sub-assembly are aligned and then tighten the retainer.

      B001FLXE08
    5. B001DJLE01
      Text in Illustration
      *a Start Mark (Fuel Tank Side)
      *b Start Mark (Retainer Side)

      Set SST on the retainer.

      SST
      09808-14030

      Tech Tips


      • Hold the fuel tank vent tube assembly upright by hand to ensure that the gasket is not moved out of position.

      • Engage the claws of SST securely with the retainer holes to secure SST.

      • Install SST while pressing the claws of SST against the retainer (toward the center of SST).

    6. B001CGGE08
      Text in Illustration
      *a Fuel Tank Side Mark
      *b Retainer Side Mark

      Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank as shown in the illustration.

      SST
      09808-14030

      Tech Tips

      Fit the tips of SST onto the ribs of the retainer.

  4. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY (for Double Tank Type)

    Click here

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


    1. B001CD6

      Install the fuel return tube sub-assembly and fuel tank main tube sub-assembly with the 2 fuel tube joint clips.

      Note


      • B001EK0E07

        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 fuel tube joint clips are on the collars of the fuel tube joints.

      • After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.

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

    2. Install the fuel return tube sub-assembly and fuel tank main tube sub-assembly to the fuel tank sub-assembly.

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


    1. B001DIR

      Install the fuel tank main tube sub-assembly, fuel return tube sub-assembly and No. 2 fuel main tube sub-assembly with the 3 fuel tube joint clips.

      Note


      • B001EK0E07

        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 fuel tube joint clips are on the collars of the fuel tube joints.

      • After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.

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

    2. Install the fuel tank main tube sub-assembly to the fuel tank sub-assembly.

    3. Install the fuel return tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

    4. Install the No. 2 fuel main tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

  7. INSTALL NO. 4 FUEL MAIN TUBE SUB-ASSEMBLY AND FUEL SUCTION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B001GCV

      Install the No. 4 fuel main tube sub-assembly and fuel suction tube sub-assembly with the 2 fuel tube joint clips.

      Note


      • B001EK0E07

        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 fuel tube joint clips are on the collars of the fuel tube joints.

      • After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.

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

    2. Install the fuel suction tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

    3. Install the No. 4 fuel main tube sub-assembly to the fuel tank sub-assembly and attach the clamp.

  8. INSTALL FUEL TANK CUSHION


    1. Install 3 new fuel tank cushions to the fuel tank sub-assembly.

  9. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank sub-assembly on a transmission jack and lift up the transmission jack.

      Note

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

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

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

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

  10. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. Connect the fuel tank to filler pipe hose to the filler pipe, and tighten the clamp to secure the hose.

  11. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. Connect the fuel tank breather tube sub-assembly Click here.

  12. CONNECT FUEL CUT OFF TUBE (for Single Tank Type)


    1. Connect the fuel cut off tube Click here.

  13. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. Connect the fuel tank breather tube sub-assembly Click here.

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


    1. Connect the fuel return tube sub-assembly and No. 2 fuel main tube sub-assembly Click here.

  15. CONNECT FUEL CUT OFF TUBE (for Double Tank Type)


    1. Connect the fuel cut off tube Click here.

  16. CONNECT NO. 4 FUEL MAIN TUBE SUB-ASSEMBLY AND FUEL SUCTION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. Connect the No. 4 fuel main tube sub-assembly and fuel suction tube sub-assembly Click here.

  17. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. Connect the fuel return tube sub-assembly Click here.

  18. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. Connect the fuel tank main tube sub-assembly Click here.

  19. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. Connect the fuel tank main tube sub-assembly Click here.

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


    1. for Type A:


      1. Install the No. 1 fuel tank protector sub-assembly with the 6 bolts.

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

    2. for Type B:


      1. Install the No. 1 fuel tank protector sub-assembly with the 4 bolts.

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

  21. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. Connect the fuel pump and fuel sender gauge connector.

    2. Install the rear floor service hole cover with the 3 screws.

  22. INSTALL REAR SEAT ASSEMBLY LH


    1. for 60/40 Split Double-folding Seat Type LH Side:

      Click here.

    2. for 60/40 Split Slide Walk-in Seat Type LH 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. BLEED AIR FROM FUEL SYSTEM

    Click here

  25. INSPECT FOR FUEL LEAK

    Click here