FUEL TANK INSTALLATION

INSTALL NO. 1 FUEL TANK HEAT INSULATOR
1. Install the heat insulator with the 4 clips.
2. Install the fuel tube clamp to the heat insulator.

INSTALL FUEL TANK TO FILLER PIPE HOSE

Install the hose to the fuel tank as shown in the illustration.

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

Tech Tips

Align the fuel tank side mark with the hose side mark when installing the hose.
Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

Text in Illustration
*1	Stopper

INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Apply a light coat of gasoline or grease to a new gasket, and install it to the fuel tank.

Text in Illustration
*1	Protrusion
*2	Groove
	Front

Install the fuel suction with pump and gauge tube into the fuel tank.

Note

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

Tech Tips

Align the protrusion of the fuel suction with pump and gauge tube with the groove of the fuel tank.

Put the retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer one complete turn by hand.
Set SST on the retainer.

SST

09808-14030
Tech Tips
- Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.
- Securely attach the claws of SST to the protrusions of the retainer and fix SST in place.
- Install SST while pressing the claws of SST against the retainer (toward the center of SST).

Text in Illustration
*1	Fuel Tank Side Mark
*2	Retainer Side Mark

Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank as shown in the illustration.

SST: 09808-14030

Tech Tips

Fit the tips of SST onto the ribs of the retainer.

INSTALL FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

Install the 3 fuel tank tubes with the 3 tube joint clips.

Note

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 tube joint clips are on the collars of the fuel tube joints.
After installing the 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	Tube Joint Clip
*a	CORRECT
*b	INCORRECT

Install the 3 fuel tank tubes to the fuel tank.

INSTALL FUEL TANK SUB-ASSEMBLY
1. Set the fuel tank on an engine lifter and raise the fuel tank.
  
  Note
  
  Do not allow the fuel tank to contact the vehicle, especially the differential.
2. Raise the engine lifter.
3. Install the 2 fuel tank bands with the 2 pins and 2 clips.
4. Connect the 2 fuel tank bands with the 2 bolts.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }

CONNECT FUEL TANK TO FILLER PIPE HOSE

Connect the hose to the filler pipe as shown in the illustration.

Text in Illustration
*1	Hose Side Mark
*2	Pipe Side Mark
*a	0 to 3 mm

Tech Tips

Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.
Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

Text in Illustration
*1	Stopper

CONNECT FUEL TANK BREATHER TUBE
1. Text in Illustration
  
  *1 Retainer
  
  Connect the fuel tank breather tube to the filler pipe and push the retainer.
  Note
  - Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
  - After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
  Tech Tips
  
  Push the parts together firmly until a "click" sound is heard.
2. Attach the fuel tube clamp.

CONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY

Text in Illustration
*1	Retainer
*2	Connector
*3	O-Ring
*4	Pipe
*5	Nylon Tube

Connect the fuel main tube and push the retainer.

Note

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

Tech Tips

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

CONNECT NO. 2 FUEL TANK BREATHER TUBE

Text in Illustration
*1	Retainer
*2	Connector
*3	O-Ring
*4	Pipe
*5	Nylon Tube

Connect the fuel tank breather tube and push the retainer.

Note

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

Tech Tips

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

CONNECT FUEL TANK RETURN TUBE

Text in Illustration
*1	Retainer
*2	Pipe
*3	Nylon Tube
*4	Connector
*5	O-Ring

Connect the fuel tank return tube and push the retainer.

Note

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

Tech Tips

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Text in Illustration
*1	Retainer
*2	Pipe
*3	Nylon Tube
*4	Connector
*5	O-Ring

Connect the fuel tank main tube and push the retainer.

Note

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

Tech Tips

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY
1. Install the fuel tank protector with the 5 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL FUEL TANK CAP ASSEMBLY
INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER
1. Connect the fuel pump and fuel sender gauge connector.
2. Install the service hole cover with new butyl tape.
3. w/ Rear Air Conditioning System:
  
  Install the air duct and 2 screws.
INSTALL FRONT FLOOR CARPET ASSEMBLY
INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH
- w/ Sliding Roof Click here
- w/o Sliding Roof Click here
INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH
- w/ Sliding Roof Click here
- w/o Sliding Roof Click here
INSTALL REAR NO. 2 SEAT ASSEMBLY
- for Face to Face Seat Type Click here
- except Face to Face Seat Type Click here
INSTALL REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type 40 Side)

Click here
INSTALL REAR NO. 1 SEAT ASSEMBLY LH (for 60/40 Split Seat Type 60 Side)

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

Click here
ADD FUEL
INSPECT FOR FUEL LEAK
1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.
  1. Connect the GTS to the DLC3.
  2. Turn the ignition switch to ON and turn the GTS on.
    
    Note
    
    Do not start the engine.
  3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
  4. Check that there are no leaks from the fuel system.
    
    If there are fuel leaks, repair or replace parts as necessary.
  5. Turn the ignition switch off.
  6. Disconnect the GTS from the DLC3.