FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK CUSHION


    1. A00329S

      Install 2 new No. 1 fuel tank cushions as shown in the illustration.

  2. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Engage the guide, and then install the No. 1 charcoal canister outlet hose to the fuel tank assembly.

  3. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Engage the 3 guides, and then install the No. 1 fuel evaporation tube sub-assembly to the fuel tank assembly.

  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Engage the 3 guides, and then install the fuel tank main tube sub-assembly to the fuel tank assembly.

  5. INSTALL FUEL TANK ASSEMBLY


    1. Support the fuel tank assembly using an engine lifter.

    2. Raise the engine lifter, then install the fuel tank assembly to the vehicle.

      Note


      • Do not drop the fuel tank assembly.

      • When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

    3. Temporarily install the fuel tank assembly with the 4 bolts.

    4. A00323DN01

      Tighten the fuel tank assembly with the 4 bolts in the order shown in the illustration.

      Torque:
      39.2 N*m  { 400 kgf*cm, 29 ft.*lbf }

    5. Connect the No. 3 parking brake cable assembly with the bolt.

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

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00322WC02
      *a Retainer
      *b Fuel Tube Connector
      *c Fuel Pipe
      *d O-ring
      A00328E Push
      A00320Y Push In

      Push the fuel tube connector onto the fuel pipe and push in the retainer to engage the lock claws.

      Note


      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tube connector and fuel pipe before performing this work.

      • After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

  7. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A00321TC02
      *a Fuel Tube Connector
      *b Retainer
      *c Fuel Pipe
      *d O-ring
      *e Rubber Hose
      A00328E Push

      Push the fuel tube connector onto the fuel pipe until the fuel tube connector makes a "click" sound.

      Note


      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tube connector and fuel pipe before performing this work.

      • After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

  8. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

    A00322ZC01
    *1 No. 1 Charcoal Canister Outlet Hose
    *2 Fuel Tank Breather Tube
    *a 0 to 3 mm (0 to 0.118 in.)
    *b 30 mm (1.18 in.)
    *c Upper
    *d 180° (Clamp Area)
    *e 20°

    1. Connect the No. 1 charcoal canister outlet hose to the fuel tank filler pipe sub-assembly as shown in the illustration.

  9. CONNECT FUEL TANK BREATHER TUBE


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

  10. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A00321UC01
      *a Upper
      *b 180° (Clamp Area)
      *c 15° (Paint Mark Area)

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

  11. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Install the No. 1 fuel tank protector with the 4 clips.

  12. INSTALL REAR FLOOR SIDE MEMBER COVER LH

    Click here

  13. INSTALL REAR FLOOR SIDE MEMBER COVER RH

    Click here

  14. ADD FUEL

  15. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here