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FUEL TANK INSTALLATION

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  1. Click here

    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. Click here

    INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. A015BO8E04

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

      Table 1. Text in Illustration
      *a Fuel Tank Side Mark
      *b Hose Side Mark
      Tip:

      • 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.

      Table 2. Text in Illustration
      *a Stopper
  3. Click here

    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. A0158D8E02

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

      Table 3. Text in Illustration
      *1 Protrusion
      *2 Groove
      A015DIT Front
      Note:

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

      Tip:

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

    3. Put the fuel pump gauge retainer on the fuel tank. While holding the fuel suction with pump and gauge tube assembly, tighten the fuel pump gauge retainer 1 complete turn by hand.

    4. A015B6RE01

      Set SST on the fuel pump gauge retainer.

      09808-14030
      Tip:

      • Hold the fuel suction with pump and gauge tube assembly upright by hand to make sure that the fuel suction tube gasket is not moved out of position.

      • Engage the claws of SST securely with the fuel pump gauge retainer holes to secure SST.

      • Install SST while pressing the claws of SST against the fuel pump gauge retainer (toward the center of SST).

    5. A015BV9E03

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

      09808-14030
      Table 4. Text in Illustration
      *1 Fuel Tank Side Mark
      *2 Fuel Pump Gauge Retainer Side Mark
      Tip:

      Fit the tips of SST onto the ribs of the fuel pump gauge retainer.

  4. Click here

    INSTALL FUEL TANK MAIN TUBE, FUEL TANK RETURN TUBE AND NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. A015984E15

      Install the 3 fuel tube joints 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.

      Table 5. Text in Illustration
      *1 Fuel Tube Joint
      *2 O-Ring
      *3 Tube Joint Clip
      *a CORRECT
      *b INCORRECT

    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. Click here

    CONNECT FUEL HOSE (for Double Tank Type)


    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. Click here

    INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. A015984E15

      Install the 2 fuel tube joints with the 2 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.

      Table 6. Text in Illustration
      *1 Fuel Tube Joint
      *2 O-Ring
      *3 Tube Joint Clip
      *a CORRECT
      *b INCORRECT

    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.

  7. Click here

    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.

      40 N*m 408 kgf*cm 30 ft.*lbf
  8. Click here

    CONNECT FUEL TANK TO FILLER PIPE HOSE (for Double Tank Type)


    1. A01555WE04

      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.

      Table 7. 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
      Tip:

      • 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.

      Table 8. Text in Illustration
      *a Stopper
  9. Click here

    CONNECT FUEL TANK TO FILLER PIPE HOSE (for Single Tank Type)


    1. A0156BQE03

      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.

      Table 9. 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
      Tip:

      • 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.

      Table 10. Text in Illustration
      *a Stopper
  10. Click here

    CONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. A015CDIE01

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

      Table 11. Text in Illustration
      *1 Retainer
      A015DIT Push
      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.

      Tip:

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

    2. Attach the fuel tube clamp.

  11. Click here

    CONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. A0157PBE01

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

      Table 12. Text in Illustration
      *1 Retainer
      A015DIT Push
      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.

      Tip:

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

    2. Attach the fuel tube clamp.

  12. Click here

    CONNECT NO. 2 FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. A01587ZE01

      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.

        Table 13. Text in Illustration
        *1 Retainer
        *2 Connector
        *3 O-Ring
        *4 Pipe
        *5 Nylon Tube
        A015DIT Push
        Tip:

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

      2. Attach the fuel tube clamp.

  13. Click here

    CONNECT NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

    Table 14. 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.

      Tip:

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

    2. Attach the fuel tube clamp.

  14. Click here

    CONNECT FUEL HOSE (for Double Tank Type)


    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.

  15. Click here

    CONNECT NO. 1 FUEL EMISSION TUBE SUB-ASSEMBLY (for Double Tank Type)


    1. A0159RYE01

      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.

        Table 15. Text in Illustration
        *1 Retainer
        *2 Connector
        *3 O-Ring
        *4 Pipe
        *5 Nylon Tube
        A015DIT Push
        Tip:

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

      2. Attach the fuel tube clamp.

    2. A0157ZAE01

      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.

        Table 16. Text in Illustration
        *1 Retainer
        *2 Pipe
        *3 Nylon Tube
        *4 Connector
        *5 O-Ring
        A015DIT Push
        Tip:

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

      2. Attach the fuel tube clamp.

  16. Click here

    CONNECT FUEL TANK RETURN TUBE (for Double Tank Type)

    Table 17. 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.

      Tip:

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

    2. Attach the fuel tube clamp.

  17. Click here

    CONNECT FUEL TANK RETURN TUBE (for Single Tank Type)


    1. A015BD0E01

      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.

      Table 18. Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Push
      Tip:

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

    2. Attach the fuel tube clamp.

  18. Click here

    CONNECT NO. 2 FUEL TANK BREATHER HOSE (for Double Tank Type)


    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.

  19. Click here

    CONNECT NO. 2 FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. A01578HE01

      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.

      Table 19. Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Push
      Tip:

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

    2. Attach the fuel tube clamp.

  20. Click here

    CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Double Tank Type)

    Table 20. 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.

      Tip:

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

    2. Attach the fuel tube clamp.

  21. Click here

    CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. A0156YDE01

      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.

      Table 21. Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring
      A015DIT Push
      Tip:

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

    2. Attach the fuel tube clamp.

  22. Click here

    INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


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

      20 N*m 204 kgf*cm 15 ft.*lbf
  23. Click here

    INSTALL FUEL TANK CAP ASSEMBLY

  24. Click here

    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.

  25. Click here

    INSTALL FRONT FLOOR CARPET ASSEMBLY

  26. Click here

    INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY LH


  27. Click here

    INSTALL FRONT QUARTER TRIM PANEL ASSEMBLY RH


  28. Click here

    INSTALL REAR NO. 2 SEAT ASSEMBLY


  29. Click here

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

    (Click here)

  30. Click here

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

    (Click here)

  31. 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).

  32. Click here

    ADD FUEL

  33. Click here

    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 engine switch on (IG) 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 engine switch off.

      6. Disconnect the GTS from the DLC3.