FUEL TANK INSTALLATION


  1. INSTALL NO. 1 FUEL TANK HEAT INSULATOR


    1. A01ERS3E01

      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. A01EPFAE02

      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.

      • A01ER10E06

        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. A01EOQTE02
      Text in Illustration
      *1 Protrusion
      *2 Groove
      A01EO1M 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. A01ENUNE01

      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. A01ES6EE03
      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. A01ENXYE12
      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.

  5. 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 }

  6. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01ENUXE02

      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.

      • A01ER10E06

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

      Text in Illustration
      *1 Stopper

  7. CONNECT FUEL TANK BREATHER TUBE


    1. A01ER8XE02
      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.

  8. CONNECT NO. 2 FUEL MAIN TUBE SUB-ASSEMBLY


    1. A01EQD3E03
      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.

  9. CONNECT NO. 2 FUEL TANK BREATHER TUBE


    1. A01EQDME03
      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.

  10. CONNECT FUEL TANK RETURN TUBE


    1. A01ENWOE03
      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.

  11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01ENPME03
      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.

  12. 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 }

  13. INSTALL FUEL TANK CAP ASSEMBLY

  14. 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. Install the air duct and 2 screws.

  15. INSTALL FRONT FLOOR CARPET ASSEMBLY

  16. INSTALL REAR NO. 1 SEAT ASSEMBLY AND REAR NO. 2 SEAT ASSEMBLY

    Click here

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  18. ADD FUEL

  19. 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.