ТОПЛИВНЫЙ БАК УСТАНОВКА

PROCEDURE


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B001D1ZE01
      Text in Illustration
      *1 Fuel Tank Side Mark
      *2 Hose Side Mark

      Align the fuel tank side mark with the hose side mark.

    2. Install the fuel tank to filler pipe hose to the fuel tank.

  2. INSTALL NO. 3 FUEL TANK PROTECTOR


    1. Install the No. 3 fuel tank protector and attach the 4 clamps.

    2. Install the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  3. INSTALL FUEL TANK VENT TUBE ASSEMBLY


    1. B001IAWC02
      *a Co-rotation Prevention Check Mark

      Apply a co-rotation prevention check mark to the fuel tank vent tube assembly.

      Tech Tips

      Perform this procedure when replacement of the fuel tank vent tube assembly is necessary.

    2. Apply a light coat of diesel fuel or grease to a new gasket and install the gasket to the fuel tank sub-assembly.

    3. B001CZ8C06
      *a Protrusion
      *b Groove

      Set the fuel tank vent tube assembly to the fuel tank sub-assembly.

      Note

      Be careful not to bend the arm of the fuel sender gauge assembly.

      Tech Tips

      Align the cutout of the fuel tank vent tube assembly to the groove of the fuel tank sub-assembly.

    4. B001EJPC02
      *a Rotational Start Point Mark (Fuel Tank Sub-assembly Side)
      *b Rotational Start Point Mark (Fuel Pump Gauge Retainer Side)

      Temporarily place the fuel pump gauge retainer by aligning the rotational start point mark of a new fuel pump gauge retainer with the rotational start point mark of the fuel tank sub-assembly while pressing the fuel tank vent tube assembly into the fuel tank sub-assembly.

    5. B001GAWC01
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Rib
      *c Cutout
      *d SST (Claw Set) Incorrect Installation Point (Rotational Start Point Mark of Fuel Pump Gauge Retainer)

      Set 4 SSTs (claw sets) to the fuel pump gauge retainer and temporarily install.

      SST
      09808-14031   ( 09808-01080, 09808-01090, 09808-01100 )

      Note


      • Align the cutout of SST (claw set) to the rib of the fuel pump gauge retainer.

      • Do not place SST on the rotational start point mark of the fuel pump gauge retainer, otherwise SST (claw set) cannot be set correctly.

    6. B001GYSC03
      *1 Fuel Pump Gauge Retainer
      *a SST (Claw Set)
      *b Hook
      B001CHY Press
      B001DEF SST (Bolt)

      While firmly pressing the claw of SST (claw set) into rib of the fuel pump gauge retainer, tighten the bolt.

    7. B001GNDC03
      *a SST (Plate)
      *b SST (Claw Set)
      B001CHY SST (Bolt)

      Temporarily install SST (plate) to SST (claw set) with 4 SSTs (bolts).

    8. B001F2IC03
      *a Center of Fuel Pump Gauge Retainer
      *b SST (Plate)

      Adjust the position of SST (plate) so that the setting hole of SST (handle) aligns with the center of the fuel pump gauge retainer.

    9. B001G7GC01
      *1 Fuel Pump Gauge Retainer
      *a SST (Plate)
      *b SST (Claw Set)
      *c SST (Bolt)
      *d Rib
      B001DLW Press

      While firmly pressing the SST (claw set) into rib of the fuel pump gauge retainer, tighten SST (bolt).

    10. B001I0HC02
      *a Co-rotation Prevention Check Mark
      *b Tightening Start Position
      *c One and Half Rotation Position

      While one person presses the fuel tank vent tube assembly into the fuel tank sub-assembly, have another person firmly press the fuel pump gauge retainer into the threads of the fuel tank sub-assembly and tighten approximately one and a half turns.

      Note


      • Do not use any tools other than SST, such as a screwdriver, etc.

      • Do not use excessive force when pressing down on SST, as the fuel tank vent tube assembly will place excessive force on the pump gauge retainer and be difficult to remove, and parts may be damaged.

      • Do not use an impact wrench or turn the SST handle with excessive force, as parts may be damaged.

      • Do not rotate the fuel pump gauge retainer when the co-rotation prevention check mark is out of place.

    11. B001HUHC02
      *a SST (Plate)
      *b Person in Charge of Tightening
      *c Person in Charge of Supporting
      *d Approximately 180°

      While one person presses the fuel tank vent tube assembly into the fuel tank sub-assembly, have another person slowly tighten approximately 180°.

    12. Check the tightening condition of the fuel pump gauge retainer.


      1. B001GP6C02
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Sub-assembly
        *a Vernier Caliper
        *b Measurement Position
        *c Measurement Height

        Using a vernier caliper, measure the upper surface dimensions of the fuel tank assembly at the 3 positions as shown in the illustration.

        Standard
        Measurement difference is within 3 mm.

        Note

        If the measurement difference is approximately 6 mm, the threads misaligned by 1 threads (6 mm) and the fuel pump gauge retainer must be installed again.

    13. B001FUIC02
      *a SST (Handle)
      *b SST (Plate)
      *c Tightening Complete Position
      *d Rotational Start Point Mark of Fuel Pump Gauge Retainer
      *e Rotational Start Point Mark of Fuel Tank Assembly
      *f Person in Charge of Tightening
      *g Person in Charge of Supporting
      B001CHY Tighten

      Install SST (handle) to SST (plate).

      SST
      09808-14031   ( 09808-01010, 09808-01020 )

    14. While one person presses the fuel tank vent tube assembly onto the fuel tank sub-assembly, have another person use SST (handle) and slowly tighten the fuel pump gauge retainer until it reaches the tightening complete position.

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


    1. B001CD6

      Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.

      Note


      • B001EK0E07

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

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

        Text in Illustration
        *1 Fuel Tube Joint
        *2 O-Ring
        *3 Fuel Tube
        *4 Fuel Tube Joint Clip
        *a CORRECT
        *b INCORRECT

    2. Install the fuel tank main tube and fuel return tube to the fuel tank.

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


    1. B001CJO

      Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.

      Note


      • B001EK0E07

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

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

        Text in Illustration
        *1 Fuel Tube Joint
        *2 O-Ring
        *3 Fuel Tube
        *4 Fuel Tube Joint Clip
        *a CORRECT
        *b INCORRECT

    2. Install the fuel tank main tube to the fuel tank.

    3. Install the fuel return tube to the fuel tank and attach the clamp.

  6. INSTALL FUEL TANK CUSHION


    1. Install 3 new fuel tank cushions to the fuel tank.

  7. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank on a transmission jack and rise the transmission jack.

      Note

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

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

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

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

  8. CONNECT FUEL TANK TO FILLER PIPE HOSE


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

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


    1. Connect the fuel tank breather tube Click here.

  10. CONNECT FUEL CUT OFF TUBE (for Single Tank Type)

  11. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. Connect the fuel tank breather tube Click here.

  12. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. Connect the fuel return tube Click here.

  13. CONNECT FUEL CUT OFF TUBE (for Double Tank Type)


    1. Connect the fuel cut off tube Click here.

  14. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)

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

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

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


    1. Install the No. 1 fuel tank protector with the 6 bolts.

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

  18. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. Connect the fuel sender gauge connector.

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

  19. INSTALL REAR SEAT ASSEMBLY LH


    1. for 60/40 Split Double-folding Seat Type LH Side:

      Install the rear seat assembly LH Click here.

    2. for 60/40 Split Slide Walk-in Seat Type LH Side:

      Install the rear seat assembly LH Click here.

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  21. BLEED AIR FROM FUEL SYSTEM

    Click here

  22. INSPECT FOR FUEL LEAK

    Click here