FUEL TANK(for 3 Door) INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK CUSHION


    1. Install new 2 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.

  5. INSTALL FUEL TANK TO FILLER PIPE HOSE


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

  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 and attach the clamp.

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

  9. INSTALL FUEL SUCTION TUBE ASSEMBLY

    Click here

  10. INSTALL FUEL TANK SUB-ASSEMBLY


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

    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 }

  11. CONNECT FUEL TANK BREATHER HOSE


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

  12. CONNECT FUEL TANK TO FILLER PIPE HOSE


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

  13. CONNECT FUEL HOSE


    1. Connect the fuel evaporation hose and fuel hose.

  14. CONNECT FUEL MAIN TUBE


    1. Connect the fuel main tube Click here.

  15. 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 }

  16. INSTALL REAR FLOOR SERVICE HOLE COVER


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

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

  17. INSTALL REAR FLOOR MAT SUPPORT PLATE

    Click here

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  19. INSPECT FOR FUEL LEAK

    Click here