FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. Install the No. 1 fuel tank heat insulator with the 4 clips.

    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.

  2. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B0018OQE07
      Text in Illustration
      *a Fuel Tank Side Mark
      *b Hose Side Mark

      Install the fuel tank to filler pipe hose to the fuel tank sub-assembly as shown in the illustration and tighten the hose clamp.

  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

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


    1. B00199YE30
      Text in Illustration
      *1 Tube Joint Clip
      *a CORRECT
      *b INCORRECT
      *c Fuel Tube Joint
      *d O-Ring

      Install the 3 fuel tube joints with the 3 tube joint clips.

      Note


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

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

    2. for G.C.C. Countries:


      1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

      2. Attach the clamp and install the fuel tank return tube sub-assembly.

      3. Attach the clamp and install the fuel tank main tube sub-assembly.

    3. except G.C.C. Countries:


      1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

      2. Attach the clamp and install the fuel tank return tube sub-assembly.

      3. Attach the clamp and install the fuel tank main tube sub-assembly.

  5. CONNECT FUEL HOSE (for Double Tank Type)


    1. for G.C.C. Countries:

      Install the fuel hose to the fuel suction tube sub-assembly, and slide the clip to secure the hose.

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


    1. B00199YE31
      Text in Illustration
      *1 Tube Joint Clip
      *a CORRECT
      *b INCORRECT
      *c Fuel Tube Joint
      *d O-Ring
      *e Fuel Tube

      Install the 2 fuel tank tubes 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 joints are 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 cannot be pulled off.

    2. Attach the clamp and install the fuel tank return tube sub-assembly.

    3. Attach the clamp and install the fuel tank main tube sub-assembly.

  7. INSTALL FUEL TANK SUB-ASSEMBLY


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

      Note

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

    2. Raise the engine lifter.

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

    4. 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 (for Double Tank Type)


    1. B001A37E06
      Text in Illustration
      *a 0 to 0.3 mm (0 to 0.0118 in.)
      *b Fuel Tank to Filler Pipe Hose Side Mark
      *c Fuel Tank Inlet Pipe Side Mark

      Connect the fuel tank to filler pipe hose to the fuel tank to filler pipe sub-assembly as shown in the illustration and tighten the hose clamp.

  9. CONNECT FUEL TANK TO FILLER PIPE HOSE (for Single Tank Type)


    1. B001A2UE04
      Text in Illustration
      *a 0 to 0.3 mm (0 to 0.0118 in.)
      *b Fuel Tank to Filler Pipe Hose Side Mark
      *c Fuel Tank Inlet Pipe Side Mark

      Connect the fuel tank to filler pipe hose to the fuel tank to filler pipe sub-assembly as shown in the illustration and tighten the hose clamp.

  10. CONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. B001AHNE02
      Text in Illustration
      *a Retainer
      B0018FC Push

      Connect the fuel tank breather tube to the fuel tank to filler pipe sub-assembly and push the retainer.

      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. Attach the fuel tube clamp.

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


    1. B001B2PE03
      Text in Illustration
      *a Retainer
      B0018FC Push

      Connect the fuel tank breather tube to the fuel tank to filler pipe sub-assembly and push the retainer.

      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. Attach the fuel tube clamp.

  12. CONNECT NO. 2 FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. B0018SVE04
      Text in Illustration
      *a Retainer
      *b Connector
      *c O-Ring
      *d Pipe
      *e Nylon Tube
      B0018FC Push

      except G.C.C. Countries:


      1. Connect the No. 2 fuel tank breather tube and push the retainer.

        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. Attach the fuel tube clamp.

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

    B00197CE05
    Text in Illustration
    *a except G.C.C. Countries *b for G.C.C. Countries
    *c Retainer *d Connector
    *e O-Ring *f Pipe
    *g Nylon Tube - -
    B0018FC Push - -

    1. Connect the No. 2 fuel tank main tube sub-assembly and push the retainer.

      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. Attach the fuel tube clamp.

  14. CONNECT FUEL HOSE (for Double Tank Type)


    1. for G.C.C. Countries:


      1. Connect the fuel hose to the pipe, and slide the clip to secure the hose.

      2. Attach the fuel tube clamp.

  15. CONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. B0018HXE03
      Text in Illustration
      *a Retainer
      *b Connector
      *c O-Ring
      *d Pipe
      *e Nylon Tube
      B0018FC Push

      except G.C.C. Countries:


      1. Connect the No. 1 fuel emission tube sub-assembly and push the retainer.

        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. Attach the fuel tube clamp.

    2. B001A2EE03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC Push

      for G.C.C. Countries:


      1. Connect the No. 1 fuel emission tube sub-assembly and push the retainer.

        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. Attach the fuel tube clamp.

  16. CONNECT FUEL TANK RETURN TUBE (for Double Tank Type)

    B001AN5E03
    Text in Illustration
    *a except G.C.C. Countries *b for G.C.C. Countries
    *c Retainer *d Pipe
    *e Nylon Tube *f Connector
    *g O-Ring - -
    B0018FC Push - -

    1. Connect the fuel tank return tube and push the retainer.

      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. Attach the fuel tube clamp.

  17. CONNECT FUEL TANK RETURN TUBE (for Single Tank Type)


    1. B001ACVE03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC Push

      Connect the fuel tank return tube and push the retainer.

      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. Attach the fuel tube clamp.

  18. CONNECT NO. 2 FUEL TANK BREATHER HOSE (for Double Tank Type)


    1. for G.C.C. Countries:


      1. Connect the No. 2 fuel tank breather hose to the pipe, and slide the clip to secure the hose.

      2. Attach the fuel pipe clamp.

  19. CONNECT NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. B0019BSE03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC Push

      Connect the No. 2 fuel tank breather tube and push the retainer.

      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. Attach the fuel tube clamp.

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

    B001ASSE03
    Text in Illustration
    *a except G.C.C. Countries *b for G.C.C. Countries
    *c Retainer *d Pipe
    *e Nylon Tube *f Connector
    *g O-Ring - -
    B0018FC Push - -

    1. Connect the fuel tank main tube sub-assembly and push the retainer.

      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. Attach the fuel tube clamp.

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


    1. B00193TE03
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-Ring
      B0018FC Push

      Connect the fuel tank main tube sub-assembly and push the retainer.

      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. Attach the fuel tube clamp.

  22. 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 }

  23. INSTALL FUEL TANK CAP ASSEMBLY

  24. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER


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

    2. Install the rear floor No. 2 service hole cover with new butyl tape.

    3. Install the air duct and 2 screws.

  25. INSTALL FRONT FLOOR CARPET ASSEMBLY

  26. INSTALL REAR SEAT ASSEMBLY


    1. Install the rear No. 1 seat assembly and rear No. 2 seat assembly Click here.

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  28. ADD FUEL

  29. INSPECT FOR FUEL LEAK

    Click here