FUEL TANK INSTALLATION


  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. A015AQUE01

      Install the heat insulator with the 4 clips.

    2. Install the fuel tube clamp to the heat insulator.

  2. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. A015BO8E02

      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.

      • A015BD6E06

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

      Text in Illustration
      *1 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. A0158D8E02
      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 1 complete turn by hand.

    4. A015B6RE01

      Set SST on the retainer.

      SST
      09808-14030

      Tech Tips


      • Hold the fuel suction 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
      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 SUB-ASSEMBLY AND FUEL TANK RETURN TUBE SUB-ASSEMBLY (for Single Tank Type)


    1. A015984E12
      Text in Illustration
      *1 Fuel Tube Joint
      *2 O-Ring
      *3 Fuel Tube
      *4 Tube Joint Clip
      *a CORRECT
      *b INCORRECT

      Install the 2 fuel tank tubes 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.

    2. Install the 2 fuel tank tubes to the fuel tank.

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


    1. A015984E12
      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 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. Install the 3 fuel tank tubes to the fuel tank.

  6. 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 }

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


    1. A0156BQE02

      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 0.3 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.

      • A015BD6E06

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

      Text in Illustration
      *1 Stopper

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


    1. A01555WE02

      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 0.3 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.

      • A015BD6E06

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

      Text in Illustration
      *1 Stopper

  9. CONNECT FUEL TANK BREATHER TUBE (for Single Tank Type)


    1. A0155S6E02
      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.

  10. CONNECT FUEL TANK BREATHER TUBE (for Double Tank Type)


    1. A015DEME02
      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.

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


    1. A015BYEE03
      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.

    2. Attach the fuel tube clamp.

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


    1. A0155RFE03
      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.

    2. Attach the fuel tube clamp.

  13. CONNECT FUEL TANK RETURN TUBE (for Single Tank Type)


    1. A015DWHE02
      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.

    2. Attach the fuel tube clamp.

  14. CONNECT FUEL TANK RETURN TUBE (for Double Tank Type)


    1. A0157JIE03
      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.

    2. Attach the fuel tube clamp.

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


    1. A015BBTE02
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 Nylon Tube
      *4 Connector
      *5 O-Ring

      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.

    2. Attach the fuel tube clamp.

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


    1. A0158WPE02
      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.

    2. Attach the fuel tube clamp.

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


    1. A015CTZE03
      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.

    2. Attach the fuel tube clamp.

  18. 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 }

  19. INSTALL FUEL TANK CAP ASSEMBLY

  20. 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.

  21. INSTALL FRONT FLOOR CARPET ASSEMBLY

  22. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY LH


  23. REMOVE FRONT QUARTER TRIM PANEL ASSEMBLY RH


  24. REMOVE REAR NO. 2 SEAT ASSEMBLY


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

    Click here

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

    Click here

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  28. ADD FUEL

  29. 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.