FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. B0018MGE01

      Install the heat insulator with the 4 clips.

    2. Install the fuel tube clamp to the 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 as shown in the illustration.

  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Click here

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


    1. B00192C
      B00199YE32

      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.

      Text in Illustration
      *a CORRECT
      *b INCORRECT
      *c Fuel Tube Joint
      *d Fuel Tube
      *e O-Ring
      *f Tube Joint Clip
    2. B001AZC

      Install the 2 fuel tubes to the fuel tank.

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


    1. B0019TP
      B00199YE33

      Install the 3 fuel tank tubes 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.

      Text in Illustration
      *a CORRECT
      *b INCORRECT
      *c Fuel Tube Joint
      *d Fuel Tube
      *e O-Ring
      *f Tube Joint Clip
    2. B001836

      Install the 3 fuel tubes to the fuel tank.

  6. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank on a engine lifter.

    2. Raise the engine lifter.

    3. B001AIF

      Install the 2 fuel tank bands with the 2 pins and 2 clips.

    4. Connect the 2 fuel tank bands with the 2 bolts.

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

  7. 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 hose to the fuel tank filler pipe as shown in the illustration.

  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 hose to the fuel tank filler pipe as shown in the illustration.

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


    1. B0018RIE04
      Text in Illustration
      *a Retainer

      Connect the fuel tank breather tube to the filler pipe 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.

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


    1. B0018DJE04
      Text in Illustration
      *a Retainer

      Connect the fuel tank breather tube to the filler pipe 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 NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. B0019N2E03
      Text in Illustration
      *a Fuel Tube
      *b Grommet

      Connect the No. 2 fuel tank breather tube to the body.

      Tech Tips

      Make sure the No. 2 fuel tank breather tube is securely inserted into the grommet.

    2. Attach the fuel tube clamp.

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


    1. B0019QUE05
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Connector
      *d Nylon Tube
      *e O-ring

      Connect the 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)


    1. B0019E8E05
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Connector
      *d Nylon Tube
      *e O-ring

      Connect the No. 2 fuel main 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.

  14. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. B00194S

      Connect the fuel tank main tube.

    2. Attach the fuel tube clamp.

  15. CONNECT FUEL TANK RETURN TUBE


    1. B0019SUE02
      Text in Illustration
      *a Retainer
      *b Pipe
      *c Nylon Tube
      *d Connector
      *e O-ring

      Connect both ends of 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.

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


    1. B001AFE

      Install the tank protector with the 5 bolts.

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

  17. INSTALL FUEL TANK CAP ASSEMBLY

  18. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. B00187OE04
      Text in Illustration
      *A for Single Tank Type
      *B for Double Tank Type

      Connect the fuel pump and fuel sender gauge connector.

    2. B0019W1

      Install the service hole cover with new butyl tape.

    3. B0018LZ

      Install the air duct and 2 screws.

  19. INSTALL FRONT FLOOR CARPET ASSEMBLY

  20. INSTALL REAR AIR DUCT GUIDE

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  21. INSTALL AIR DUCT PLUG

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  22. INSTALL REAR FLOOR MAT REAR SUPPORT PLATE

    Click here

  23. INSTALL REAR DOOR SCUFF PLATE LH

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  24. INSTALL REAR DOOR SCUFF PLATE RH

    Click here

  25. INSTALL REAR STEP COVER

    Click here

  26. INSTALL REAR NO. 2 SEAT PROTECTOR

    Click here

  27. INSTALL REAR NO. 1 SEAT PROTECTOR

    Click here

  28. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH

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  29. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH

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  30. BLEED AIR FROM FUEL SYSTEM

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  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.

  32. CHECK SRS WARNING LIGHT

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  33. ADD FUEL

  34. INSPECT FOR FUEL LEAK

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