FUEL TANK INSTALLATION


  1. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00E8HI

      Attach the 2 clamps and install the fuel tank main tube.

  2. INSTALL FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A00E9L6

      Attach the 2 clamps and install the fuel tank return tube.

  3. INSTALL FUEL TANK CUSHION


    1. A00E6Q2E01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

      Install a new No. 1 fuel tank cushion and 3 new No. 2 fuel tank cushions at the locations shown in the illustration.

  4. INSTALL FUEL TANK ASSEMBLY


    1. Using a transmission jack, support the fuel tank.

    2. Raise the transmission jack and install the fuel tank to the vehicle.

      Note


      • Do not drop the fuel tank.

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

    3. A00EATQ

      Install the 2 fuel tank bands with the 4 bolts.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

    4. Connect the fuel tank main tube.


      1. A00E9FZE01

        Align the fuel tube connector with the pipe, push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, and then push the retainer up until the claws lock.

        Note


        • Check that there are no scratches or foreign objects around the connecting part of the fuel tube connector and pipe before starting this step.

        • After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling on the fuel tube connector.

    5. Connect the fuel tank return tube.


      1. A00E9JUE01

        Align the fuel tube connector with the pipe, push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank return tube to the pipe, and then push the retainer up until the claws lock.

        Note


        • Check that there are no scratches or foreign objects around the connecting part of the fuel tube connector and pipe before starting this step.

        • After connecting the fuel tank return tube, check that the fuel tank return tube is securely connected by pulling on the fuel tube connector.

    6. A00EAJH

      Connect the parking brake cable with the 2 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    7. A00E6V1E01

      Connect the breather hose to the fuel tank filler pipe and tighten the hose clamp bolt so that the clamp is as shown in the illustration.

      Note

      After connecting the breather hose, check that the evaporation vent tube clamp is securely connected to the fuel tank.

  5. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A00EA2OE01

      Connect the filler pipe hose to the fuel tank and tighten the hose clamp bolt so that the clamp is as shown in the illustration.

      Note

      Be sure to tighten the hose clamp so that it is at the correct angle.

  6. INSTALL REAR FLOOR SIDE MEMBER COVER RH


    1. A00EADC

      Install the rear floor side member cover RH with the clip and 2 grommets.

  7. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. A00EA56

      Install the protector with the 3 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  8. INSTALL TAILPIPE ASSEMBLY


    1. Check the free length of the compression spring.


      1. A00E9UU

        Using a vernier caliper, measure the free length of the compression spring.

        Minimum length
        38.5 mm (1.52 in.)

        If the free length is less than the minimum, replace the compression spring.

    2. Connect the tailpipe to the 4 exhaust pipe supports.

    3. Install a new gasket to the front exhaust pipe.

    4. Install the tailpipe and 2 compression springs with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  9. ADD FUEL

  10. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. A00EAPVE02
      Text in Illustration
      *1 Gasket

      Apply a light coat of diesel fuel to a new gasket and install the gasket to the fuel tank.

    2. Install the fuel tank vent tube to the fuel tank.

      Note

      Make sure that the fuel sender gauge arm does not bend.

    3. A00E981E02
      Text in Illustration
      *1 Notch
      *2 Protrusion

      Align the protrusions of the fuel tank vent tube with the notches of the fuel tank.

  11. INSTALL FUEL PUMP GAUGE RETAINER


    1. A00E8FLE01

      While holding the fuel tank vent tube by hand to prevent it from tilting, align the starting marks on the fuel pump gauge retainer and fuel tank and tighten the fuel pump gauge retainer 180° by hand.

      Tech Tips


      • Check that there is no damage, dents, foreign matter or other defect on the threads of the fuel tank.

      • The diameter of a supplied fuel pump gauge retainer is larger than that of the factory-installed retainer, anticipating that the fuel tank swells and expands over time. If the diameter of the factory-installed retainer is too small to reinstall, use a supplied fuel pump gauge retainer.

    2. A00E8URE02

      Using a 6 mm socket, install SST to the fuel pump gauge retainer.

      SST
      09808-14020

      Tech Tips


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

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

    3. A00E8S1E01

      Tighten the fuel pump gauge retainer approximately 270° so that the start mark on the retainer comes within the range shown in the illustration.

      Note


      • Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.

      • Tighten the retainer by turning it clockwise while holding SST down. Do not allow the protrusions of the fuel tank vent tube to slip out of their notches on the fuel tank.

      Tech Tips

      The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.

  12. INSTALL TANK SUCTION TUBE SUPPORT


    1. A00EAWS

      Attach the 2 claws to install suction tube support.

    2. A00E7KP

      Install the tube.

      Note

      Securely install the tube by pushing on it until it makes a clicking sound.

  13. CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A00E6O9E01

      Push the fuel tube joint into the plug of the fuel tank vent tube, and then install the tube joint clip.

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • Check that the tube joint clip is on the collar of the fuel tube joint.

      • After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

  14. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A00E7E0E01

      Push the fuel tube joint into the plug of the fuel tank vent tube, and then install the tube joint clip.

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joint is inserted securely.

      • Check that the tube joint clip is on the collar of the fuel tube joint.

      • After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.

  15. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. A00E9ND

      Connect the sender gauge connector.

    2. Install the rear floor service hole cover with new butyl tape.

      Note

      Be careful that the rear floor service hole cover does not overlap the protrusions of the floor panel when installing.

  16. BLEED AIR FROM FUEL SYSTEM


    1. A010OM8

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A010PR6E03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A010QBAE04

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.


      1. When no DTCs are output, the air bleeding is completed.

      2. If any DTCs are output, proceed to the next step.

    13. Clear the DTCs Click here.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  17. INSPECT FOR FUEL LEAK

    Tech Tips

    Using the intelligent tester to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.


    1. Perform Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Enter the following menus: Powertrain / Engine / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop/Start

        Performs inspection of the high pressure fuel system.


        • Engine Speed: 2050 rpm

        • Fuel Pressure: 172000 kPa

        • Target Common Rail Pressure: 176000 kPa

        • Target Pump SCV Current: 1400 mA

        • MAP: 176 kPa

        • MAF: 39 g/sec.

  18. INSPECT FOR EXHAUST GAS LEAK


    1. Check that there are no exhaust gas leaks from the points (connection areas of the exhaust pipes and installation areas of each sensor) shown in the illustration.

      A00EAFQE01

  19. INSTALL REAR SEAT CUSHION ASSEMBLY


    1. for Sedan:

      Install the rear seat cushion assembly Click here.

    2. for Wagon:

      Install the rear seat cushion assembly Click here.