FUEL TANK(w/o Canister Pump Module) INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. Install the No. 2 fuel tank protector and No. 3 fuel tank protector to the fuel tank assembly.

    2. Install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly.

      Tech Tips

      Install the No. 1 fuel tank protector sub-assembly after installing the No. 2 fuel tank protector and No. 3 fuel tank protector.

  2. INSTALL FUEL TANK CUSHION


    1. Install the fuel tank bracket, 2 fuel tank cushions and fuel tank cushion set to the fuel tank assembly.

    2. Install 5 new No. 6 fuel tank cushions to the fuel tank assembly.

  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Engage the 2 clamps to install the No. 3 fuel tube clamp and No. 5 fuel tube clamp to the fuel tank assembly.

    2. Engage the 2 clamps to install the fuel tank main tube sub-assembly to the fuel tank assembly.

  4. INSTALL CHARCOAL CANISTER OUTLET HOSE


    1. Engage the clamp to install the No. 4 fuel tube clamp to the fuel tank assembly.

    2. Engage the clamp to install the charcoal canister outlet hose to the fuel tank assembly.

  5. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Install the No. 1 fuel evaporation tube sub-assembly to the fuel tank assembly.

  6. INSTALL FUEL TANK ASSEMBLY


    1. Set the fuel tank assembly on an engine lifter with attachments.

      Tech Tips

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Using the engine lifter, slowly raise the fuel tank assembly, and then install the fuel tank assembly with the 2 nuts, 4 bolts and 2 No. 1 fuel tank band sub-assemblies.

      Torque:
      Nut
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }
      Bolt
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

      Note


      • Be careful not to drop the fuel tank assembly.

      • When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

  7. INSTALL REAR BODY MOUNTING CUSHION SUB-ASSEMBLY LH

    Click here

  8. INSTALL REAR BODY MOUNTING CUSHION SUB-ASSEMBLY RH

    Click here

  9. INSTALL PARKING BRAKE CABLE ASSEMBLY


    1. Install the No. 2 parking brake cable assembly and No. 3 parking brake cable assembly with the 2 bolts and 2 nuts.

      Torque:
      Bolt
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
      Nut
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Engage the 4 clamps.

  10. CONNECT CHARCOAL CANISTER OUTLET HOSE


    1. Connect the charcoal canister outlet hose to the No. 6 fuel tank breather tube.

  11. CONNECT FUEL TANK BREATHER TUBE


    1. B0075S8C07
      *1 Fuel Tank Breather Tube
      *2 Fuel Tank Breather Tube Connector
      *a Alignment Mark
      *b Up
      *c 180°

      Align the alignment marks, connect the fuel tank breather tube to the fuel tank breather tube connector and tighten the clamp to secure it.

      Tech Tips

      Make sure the bolt of the clamp is positioned within the area shown in the illustration.

    2. Engage the 2 clamps to connect the fuel tank breather tube to the breather tube clamp and No. 2 evaporation vent tube clamp.

  12. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B0074YZC03
      *a Up
      *b 120°

      Connect the fuel tank to filler pipe hose to the fuel tank assembly and tighten the clamp to secure it.

      Tech Tips

      Make sure the bolt of the clamp is positioned within the area shown in the illustration.

  13. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Connect the No. 1 fuel evaporation tube sub-assembly to the fuel pipe.

      Click here

  14. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. for LH Side:


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

        Click here

    2. for RH Side:


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

        Click here

  15. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  16. ADD FUEL

  17. INSTALL FUEL TANK VENT TUBE ASSEMBLY

    Click here

  18. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here