FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL SENDER GAUGE ASSEMBLY

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  2. INSTALL FUEL TUBE GROMMET


    1. Install the 3 fuel tube grommets to the fuel tank assembly.

  3. INSTALL NO. 5 FUEL TUBE CLAMP


    1. Install the No. 5 fuel tube clamp to the fuel tank assembly.

  4. INSTALL FUEL TANK RETURN TUBE


    1. Install the fuel tank return tube to the No. 5 fuel tube clamp and 3 fuel tube grommets.

  5. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Install the fuel tank main tube sub-assembly to the No. 5 fuel tube clamp and 3 fuel tube grommets.

  6. INSTALL FUEL TANK VENT TUBE ASSEMBLY


    1. Install a new gasket onto the fuel tank vent tube assembly.

    2. Connect the 2 fuel hoses, slide the 2 clamps to secure the hoses and install the fuel tank vent tube assembly into the fuel tank assembly.

      Note

      Do not damage the fuel tank vent tube assembly.

  7. INSTALL FUEL TANK VENT TUBE SET PLATE


    1. Install the fuel tank vent tube set plate with the 8 bolts.

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

  8. CONNECT FUEL TANK RETURN TUBE


    1. A00YW9HC01
      *1 Fuel Tube
      *2 Fuel Tube Joint
      *3 Tube Joint Clip
      *4 O-Ring
      *5 Collar
      *a CORRECT
      *b INCORRECT

      Push the fuel tube joint into the plug of the fuel tank vent tube assembly, and then install the tube joint clip.

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • Check that the fuel tube joint clip is on the collar of the fuel tube joint.

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

      • Be careful not to damage any clip. If a clip is damaged, replace it.

  9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    A00YW9HC01
    *1 Fuel Tube
    *2 Fuel Tube Joint
    *3 Tube Joint Clip
    *4 O-Ring
    *5 Collar
    *a CORRECT
    *b INCORRECT

    1. Push the fuel tube joint into the plug of the fuel tank vent tube assembly, and then install the tube joint clip.

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • Check that the fuel tube joint clip is on the collar of the fuel tube joint.

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

      • Be careful not to damage any clip. If a clip is damaged, replace it.

  10. INSTALL FUEL EMISSION HOSE


    1. Attach the clamp and install the fuel emission hose.

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  11. INSTALL FUEL TANK ASSEMBLY


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

    2. Lift up the engine lifter.

    3. Connect the fuel sender gauge connector.

      Note

      Be careful not to cut the wire harness.

    4. Connect the wire harness to the 2 fuel tube grommets.

    5. Install the No. 1 fuel tank band sub-assembly with the 2 bolts.

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

    6. Install the No. 1 fuel tank band sub-assembly LH with the 2 bolts.

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

    7. Install the No. 2 fuel tank band sub-assembly with the 2 bolts.

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

  12. CONNECT FUEL TANK BREATHER HOSE


    1. Connect the fuel tank breather hose to the fuel tank assembly.

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  13. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A00YTW4C02
      *1 Stopper
      *2 Protrusion
      *a Top
      *b Front
      *c Bottom of Fuel Tank

      Connect the fuel tank to filler pipe hose to the fuel tank assembly and tighten the hose clamp.

      Tech Tips

      Make sure the hose clamp is oriented as shown in the illustration.

  14. CONNECT FUEL TANK RETURN TUBE


    1. Connect the fuel tank return tube to the fuel pipe, and slide the clamp to secure it.

  15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Connect the fuel tank main tube sub-assembly to the fuel pipe.

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  16. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY


    1. Connect the No. 2 parking brake cable assembly with the 2 bolts.

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

  17. INSTALL NO. 1 FLOOR UNDER COVER


    1. Attach the 2 clips and install the No. 1 floor under cover with the 2 nuts.

  18. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Attach the 3 clips and install the No. 1 fuel tank protector with the nut.

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

  19. INSTALL FRONT FLOOR COVER


    1. Install the front floor cover with the bolt and nut.

      Torque:
      for bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Attach the 4 clips.

  20. BLEED AIR FROM FUEL SYSTEM

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  21. INSPECT FOR FUEL LEAK

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