FUEL TANK (for TMMK Made) INSTALLATION


  1. INSTALL NO. 1 FUEL TANK CUSHION


    1. B000IDY

      Install 5 new No. 1 fuel tank cushions as shown in the illustration.

  2. INSTALL FUEL TANK BREATHER HOSE


    1. B000NO7E01
      Text in Illustration
      *a Up
      *b 120°
      *c 2 to 7 mm (0.0787 to 0.276 in.)
      *d 0 to 3 mm (0 to 0.118 in.)

      Install the fuel tank breather hose to the fuel tank sub-assembly and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  3. INSTALL NO. 1 FUEL TUBE CLAMP


    1. Install the No. 1 fuel tube clamp to the fuel tank sub-assembly.

  4. INSTALL CHARCOAL CANISTER OUTLET HOSE


    1. Engage the No. 2 fuel tube clamp to install charcoal canister outlet hose to the fuel tank sub-assembly.

  5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Engage the clamp to install the fuel tank main tube sub-assembly to the fuel tank sub-assembly.

  6. INSTALL FUEL TANK SUB-ASSEMBLY


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

      Tech Tips

      Using height adjustment attachments and plate lift attachments, keep the fuel tank sub-assembly horizontal.

    2. Using the engine lifter, slowly raise the fuel tank sub-assembly, and then install the fuel tank sub-assembly, 2 fuel tank bands with the 4 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

      Note


      • Be careful not to drop the fuel tank assembly.

      • When installing the fuel tank sub-assembly, tilt it slightly to prevent it from interfering with the surrounding parts.

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B000LDSE03
      Text in Illustration
      *a Retainer
      *b Up
      *c 90°
      *d 120° (Retainer Area)
      B000K70 Push
      B000IB9 Push in

      Push the fuel tank to filler pipe hose to the fuel tank sub-assembly and push in the retainer to engage the lock claws.

      Note


      • Check that there are no scratches or foreign matter around the connected parts of the fuel tank to filler pipe hose connector and fuel tank sub-assembly before performing this work.

      • After connecting the fuel tank to filler pipe hose, check that the fuel tank to filler pipe hose is securely connected by pulling on the fuel tank to filler pipe hose connector.

      Tech Tips

      Make sure the retainer of the fuel tank to filler pipe hose is within the area shown in the illustration.

  8. CONNECT FUEL TANK BREATHER HOSE


    1. Connect the fuel tank breather hose and slide the clip to secure it.

  9. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. B000LRME02
      Text in Illustration
      *1 Fuel Emission Hose
      *2 No. 1 Charcoal Canister Outlet Hose
      *a Up
      *b 120°

      Connect the No. 1 charcoal canister outlet hose and slide the clip to secure it.

      Tech Tips

      Engage the clip within the area shown in the illustration.

  10. CONNECT FUEL EMISSION HOSE


    1. Connect the fuel emission hose and slide the clip to secure it.

  11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    Note

    Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


    1. B000I7PE04
      Text in Illustration
      *a Retainer
      *b Fuel Tube Connector
      *c Nylon Tube
      *d O-ring
      *e Fuel Pipe
      *f Claw
      B000K70 Push
      B000IB9 Push in

      Connect the fuel tank main tube sub-assembly.


      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

      2. Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

  12. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Install the No. 1 fuel tank protector to the fuel tank sub-assembly with the 3 clips.

  13. INSTALL REAR NO. 1 STABILIZER BAR BRACKET


    1. Install the 2 rear No. 1 stabilizer bar brackets with the 4 nuts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  14. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 3 parking brake cable assembly with the nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  15. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 2 parking brake cable assembly with the nut.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  16. INSTALL NO. 1 FLOOR UNDER COVER


    1. Install the No. 1 floor under cover with the 2 bolts, 3 nuts, screw and 2 clips.

      Torque:
      Bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Nut
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  17. INSTALL NO. 2 FLOOR UNDER COVER


    1. Install the No. 2 floor under cover with the 2 bolts, 3 nuts, screw and 2 clips.

      Torque:
      Bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Nut
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  18. INSTALL CENTER EXHAUST PIPE ASSEMBLY

    Click here

  19. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  20. ADD FUEL

  21. INSPECT FOR EXHAUST GAS LEAK