FUEL TANK(w/o Canister Pump Module) INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. Install the No. 2 fuel tank protector and No. 3 fuel tank protector to the fuel tank assembly.

    2. Install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly.

      Tech Tips

      Install the No. 1 fuel tank protector after installing the No. 2 fuel tank protector and No. 3 fuel tank protector.

  2. INSTALL FUEL TANK CUSHION


    1. Install 5 new No. 6 fuel tank cushions to the fuel tank assembly.

    2. Install the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set to the fuel tank assembly.

  3. INSTALL FUEL TUBE


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

    2. Install the fuel tank return tube and fuel tank main tube sub-assembly to the fuel tank assembly with the clamp.

  4. INSTALL CHARCOAL CANISTER OUTLET HOSE


    1. Install the charcoal canister outlet hose and No. 4 fuel tube clamp to the fuel tank assembly.

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


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

  6. INSTALL FUEL TANK ASSEMBLY


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

    2. Using the engine lifter, slowly raise the fuel tank assembly, and then install the fuel tank assembly with the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.

      Torque:
      Nut
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }
      Bolt
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

      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.

  7. INSTALL REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

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  8. INSTALL REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

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  9. INSTALL PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly with the 2 bolts, 2 nuts and 4 clamps.

      Torque:
      Bolt
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
  10. CONNECT CHARCOAL CANISTER OUTLET HOSE


    1. Connect the charcoal canister outlet hose to the No. 6 fuel tank breather tube.

  11. CONNECT FUEL TANK BREATHER TUBE


    1. B003X4PC03
      *1 Fuel Tank Breather Tube
      *2 Fuel Tank Breather Tube Connector
      *a Alignment Mark
      *b Top

      Align the alignment marks, connect the fuel tank breather tube to the fuel tank breather tube connector and tighten the clamp to secure it.

      Tech Tips

      Make sure the clamp bolt is within the area shown in the illustration.

    2. Connect the fuel tank breather tube to the 2 hose clamps.

  12. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B003U4OC01
      *a Upper

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

      Tech Tips

      Make sure the clamp bolt is within the area shown in the illustration.

  13. INSTALL FUEL TUBE


    1. B003VUCC01
      *a Retainer
      *b Fuel Tube Connector
      *c O-ring
      *d Fuel Pipe
      B003WAF Push
      B003U82 Push In

      Connect the No. 1 fuel evaporation tube sub-assembly.

      Note

      Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


      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.

    2. for Half Cover Type:


      1. Install the protector to the No. 1 fuel evaporation tube sub-assembly.

    3. B003UETC01
      *a Retainer
      *b Fuel Tube Connector
      *c Nylon Tube
      *d O-ring
      *e Fuel Pipe
      B003WAF Push
      B003U82 Push In

      Connect the fuel tank return tube and fuel tank main tube sub-assembly.

      Note

      Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


      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.

    4. for Half Cover Type:


      1. Install the 2 protectors to the fuel tank return tube and fuel tank main tube sub-assembly.

  14. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  15. ADD FUEL

  16. INSTALL FUEL TANK VENT TUBE ASSEMBLY

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  17. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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