FUEL TANK(for 5 Door) INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B001D1ZE03
      Text in Illustration
      *a Fuel Tank Sub-assembly Side Mark
      *b Hose Side Mark

      Align the fuel tank sub-assembly side mark with the hose side mark.

    2. Install the fuel tank to filler pipe hose to the fuel tank sub-assembly.

  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 SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

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


    1. B001HBK

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

      Note


      • B001EK0E17

        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
        *a Fuel Tube Joint
        *b O-Ring
        *c Fuel Tube
        *d Fuel Tube Joint Clip
        *e CORRECT
        *f INCORRECT

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

  5. 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. B001FC2

      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


      • B001EK0E17

        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
        *a Fuel Tube Joint
        *b O-Ring
        *c Fuel Tube
        *d Fuel Tube Joint Clip
        *e CORRECT
        *f INCORRECT

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

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

  6. INSTALL FUEL TANK CUSHION


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

  7. INSTALL FUEL TANK SUB-ASSEMBLY


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

      Note

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

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

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

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

  8. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. Connect the fuel tank to filler pipe hose to the filler pipe.

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


    1. Connect the fuel cut off tube Click here.

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


    1. Connect the fuel cut off tube Click here.

  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 TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)


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

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


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

  14. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY


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

  15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


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

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


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

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

  17. 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.

  18. INSTALL REAR SEAT ASSEMBLY LH


    • for 60/40 Split Double-folding Seat Type LH Side: Click here

    • for 60/40 Split Slide Walk-in Seat Type LH Side: 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