FUEL TANK INSTALLATION


  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. Install the No. 1 fuel tank heat insulator with the 4 clips.

    2. Install the fuel tube clamp to the No. 1 fuel tank heat insulator.

  2. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. A015BO8E03

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

      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.

      • A015BD6E07

        Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

      Text in Illustration
      *a Stopper

  3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


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

    2. A0158D8E03
      Text in Illustration
      *1 Protrusion
      *2 Groove
      A015DIT 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.

    3. 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.

    4. A015837E01

      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).

    5. A0156N1E02
      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.

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


    1. A015984E15
      Text in Illustration
      *1 Fuel Tube Joint
      *2 O-Ring
      *3 Tube Joint Clip
      *a CORRECT
      *b INCORRECT

      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.

    2. for G.C.C. Countries:


      1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

      2. Attach the clamp and install the fuel tank return tube sub-assembly.

      3. Attach the clamp and install the fuel tank main tube sub-assembly.

    3. except G.C.C. Countries:


      1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.

      2. Attach the clamp and install the fuel tank return tube sub-assembly.

      3. Attach the clamp and install the fuel tank main tube sub-assembly.

  5. INSTALL FUEL HOSE


    1. for G.C.C. Countries:

      Install the fuel hose to the fuel suction tube sub-assembly, and slide the clip to secure the hose.

  6. INSTALL FUEL TANK SUB-ASSEMBLY


    1. Set the fuel tank sub-assembly on an engine lifter and raise the fuel tank sub-assembly.

      Note

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

    2. Raise the engine lifter.

    3. Install the 2 fuel tank band sub-assemblies with the 2 pins and 2 clips.

    4. Connect the 2 fuel tank band sub-assemblies with the 2 bolts.

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

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01555WE05

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

      Text in Illustration
      *a 0 to 0.3 mm (0 to 0.0118 in.)
      *b Fuel Tank to Filler Pipe Hose Side Mark
      *c Fuel Tank Inlet Pipe Side Mark

      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.

      • A015BD6E07

        Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.

      Text in Illustration
      *a Stopper

  8. CONNECT FUEL TANK BREATHER TUBE


    1. A015DC4E02
      Text in Illustration
      *1 Retainer
      A015DIT Push

      Connect the fuel tank breather tube to the fuel tank to filler pipe sub-assembly 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.

  9. CONNECT NO. 2 FUEL TANK BREATHER TUBE


    1. A01587ZE01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      A015DIT Push

      except G.C.C. Countries:


      1. Connect the No. 2 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.

      2. Attach the fuel tube clamp.

  10. CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY

    A01582SE01
    Text in Illustration
    *1 Retainer *2 Connector
    *3 O-Ring *4 Pipe
    *5 Nylon Tube - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    A015DIT Push - -

    1. Connect the No. 2 fuel tank main tube sub-assembly 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.

  11. CONNECT FUEL HOSE


    1. for G.C.C. Countries:


      1. Connect the fuel hose to the pipe, and slide the clip to secure the hose.

      2. Attach the fuel tube clamp.

  12. CONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY


    1. A0159RYE01
      Text in Illustration
      *1 Retainer
      *2 Connector
      *3 O-Ring
      *4 Pipe
      *5 Nylon Tube
      A015DIT Push

      except G.C.C. Countries:


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

    2. A0157ZAE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Push

      for G.C.C. Countries:


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

  13. CONNECT FUEL TANK RETURN TUBE

    A01554EE01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    A015DIT Push - -

    1. 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.

    2. Attach the fuel tube clamp.

  14. CONNECT NO. 2 FUEL TANK BREATHER HOSE


    1. for G.C.C. Countries:


      1. Connect the No. 2 fuel tank breather hose to the pipe, and slide the clip to secure the hose.

      2. Attach the fuel pipe clamp.

  15. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    A015AS7E01
    Text in Illustration
    *1 Retainer *2 Pipe
    *3 Nylon Tube *4 Connector
    *5 O-Ring - -
    *a except G.C.C. Countries *b for G.C.C. Countries
    A015DIT Push - -

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

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


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

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

  17. INSTALL FUEL TANK CAP ASSEMBLY

  18. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER


    1. Connect the fuel pump and fuel sender gauge connector.

    2. Install the rear floor No. 2 service hole cover with new butyl tape.

    3. w/ Rear Air Conditioning System:

      Install the air duct and 2 screws.

  19. INSTALL FRONT FLOOR CARPET ASSEMBLY

  20. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH


  21. INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH


  22. INSTALL REAR NO. 2 SEAT ASSEMBLY


  23. INSTALL REAR NO. 1 SEAT ASSEMBLY RH (for 60/40 Split Seat Type 40 Side)

    Click here

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

    Click here

  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  26. CHECK SRS WARNING LIGHT

    Click here

  27. ADD FUEL

  28. 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.