FUEL TANK(for 3 Door) INSTALLATION

PROCEDURE

1. INSTALL NO. 1 FUEL TANK CUSHION

   
   

   1. Install 2 new No. 1 fuel tank cushions to the fuel tank sub-assembly.

2. INSTALL FUEL TUBE GROMMET

   
   

   1. Attach the clamp to install the fuel tube grommet.

3. INSTALL FUEL TANK FILLER PIPE LOWER SUB-ASSEMBLY

   
   

   1. Install a new gasket and the fuel tank filler pipe lower sub-assembly with the 8 screws.

      Torque:

      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

4. INSTALL FUEL TANK BREATHER HOSE

   
   

   1. Install the fuel tank breather hose to the fuel tank sub-assembly, and tighten the clamp to secure the hose.

5. INSTALL FUEL TANK TO FILLER PIPE HOSE

   
   

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

6. INSTALL FUEL SENDER GAUGE ASSEMBLY

   
   

   1. Install a new gasket and the fuel sender gauge assembly with the 5 screws.

      Torque:

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

      Note

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

7. INSTALL FUEL CUT OFF VALVE ASSEMBLY

   
   

   1. Install the fuel cut off valve assembly to the fuel tank sub-assembly.

8. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

   
   

   1. Install a new gasket and the No. 1 fuel evaporation tube sub-assembly with the 4 screws.

      Torque:

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

9. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY

   
   

   1. Install a new gasket and the fuel tank vent tube sub-assembly with the 7 screws and attach the 2 clamps.

      Torque:

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

10. INSTALL FUEL TANK CHECK VALVE

    
    

    1. Connect the hose and install the fuel tank check valve.

11. INSTALL NO. 4 FUEL TUBE CLAMP

    
    

    1. Install the No. 4 fuel tube clamp to the fuel tank check valve and attach the clamp.

12. INSTALL FUEL TANK SUB-ASSEMBLY

    
    

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

    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 }

13. CONNECT FUEL TANK BREATHER HOSE

    
    

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

14. 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.

15. CONNECT FUEL HOSE

    
    

    1. Connect the 2 fuel hoses to the fuel tank vent tube sub-assembly, and slide the 2 clamps to secure the hoses.

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 REAR FLOOR SERVICE HOLE COVER

    
    

    1. Connect the fuel sender gauge connector and fuel tank ground connector.

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

18. INSTALL REAR FLOOR MAT SUPPORT PLATE

    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. BLEED AIR FROM FUEL SYSTEM

    Click here

21. INSPECT FOR FUEL LEAK

    Click here