FUEL TANK INSTALLATION

PROCEDURE

INSTALL NO. 2 FUEL TANK PROTECTOR
1. Install the No. 2 fuel tank protector to the fuel tank.
INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
1. Install the No. 1 fuel tank protector to the fuel tank.
INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Install the fuel tube 6 clamps.
2. Install the fuel tank main tube to the fuel tank with the 6 clamps.
INSTALL FUEL TANK RETURN VENT TUBE
1. Install the fuel tank return vent tube to the fuel tank.
INSTALL FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY
1. *1 Push
  
  *2 Retainer
  
  Install the canister tube to the fuel tank.
  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.
INSTALL NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
1. Install new gasket and the breather tube with the 4 screws.
  
  Torque:
  
  1.5 N*m { 15 kgf*cm, 13 in.*lbf }
INSTALL FUEL TANK ASSEMBLY
1. Set the fuel tank on a engine lifter and raise the fuel tank.
  
  Note
  
  Do not allow the fuel tank to contact the vehicle, especially the differential.
2. Temporarily install the 2 fuel tank bands with the 4 bolts.
3. Tighten the bolts in the front.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
4. *1 Fulcrum Length
  
  Using SST, a torque wrench and union nut wrench, tighten the bolts in the rear.
  
  SST
  
  09961-00950
  
  Torque:
  
  without SST
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
  
  with SST
  
  22.8 N*m { 232 kgf*cm, 17 ft.*lbf }
  Tech Tips
  
  Use a torque wrench with a fulcrum length of 180 mm (7.09 in).
  
  Make sure union nut wrench, SST and torque wrench are connected in a straight line. Fulcrum Length
CONNECT FUEL TANK TO FILLER PIPE HOSE
1. Connect the filler pipe hose to the fuel tank.
CONNECT NO. 1 FUEL TANK BREATHER TUBE SUB-ASSEMBLY
1. *1 Upper
  
  *2 Front Side of Vehicle
  
  Connect the breather tube.
  
  Tech Tips
  
  The direction of the hose clamp is indicated in the illustration.
CONNECT FUEL TANK TO CANISTER TUBE SUB-ASSEMBLY
1. Connect the canister tube.
  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.
CONNECT FUEL TANK RETURN VENT TUBE
1. Connect the fuel tank return vent tube.
  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.
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Connect the fuel tank main tube LH.
  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. Connect the fuel tank main tube RH.
  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.
INSTALL FUEL TANK PROTECTOR BRACKET SIDE
1. Install the protector with the 2 nuts.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
INSTALL FUEL TANK FILLER PIPE PROTECTOR
1. Install the protector with the 2 clips and 2 nuts.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Install a new gasket and sender gauge to the fuel tank with the 5 screws.
  
  Torque:
  
  1.5 N*m { 15 kgf*cm, 13 in.*lbf }
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the fuel sender gauge connector.
2. Install the service hole cover with new butyl tape.
INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY
1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.
2. Connect the fuel hose, and install the fuel suction with pump and gauge tube to the fuel tank.
  Note
  
  Be careful not to bend the arm of the fuel sender gauge.
  
  When connecting the fuel hose, do not forcibly pull the hose.
INSTALL FUEL TANK VENT TUBE SET PLATE
1. *1 Protrusion
  
  *2 Cutout
  
  Install the No. 2 fuel tank protector and set plate with the 8 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
  
  Tech Tips
  
  Align the protrusion of the set plate with the cutout of the fuel suction with pump and gauge tube.
2. Install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips.
  Note
  
  Check that there are no scratches or foreign objects on the connecting parts.
  
  Check that the fuel tube joint is 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 have not been pulled off.
INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
1. Connect the connector.
2. Install the service hole cover with new butyl tape.
INSTALL REAR NO. 1 AND NO. 2 SEAT ADJUSTER ASSEMBLY
- for Power Seat:
  
  Click here
- for Ottoman:
  
  Click here
INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Seat Type)

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INSTALL SERVICE PLUG GRIP

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CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSTALL BATTERY SERVICE HOLE COVER LH

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INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)

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INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

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INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

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ADD FUEL
INSPECT FOR FUEL LEAK

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