FUEL TANK INSTALLATION


  1. INSTALL NO. 1 EVAPORATION VENT TUBE CLAMP


    1. A0118MT

      Engage the 2 claws and install the No. 1 evaporation vent tube clamp.

  2. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. A011BWUE01
      Text in Illustration
      *1 Arrows
      *2 Recession

      Insert the fuel tank vent tube from the sender gauge side, in the direction indicated by the arrows on the fuel tank, run the tube along the bottom edge of the fuel tank, and then pull it out on the fuel pump side.

      Note

      Do not run the fuel tank vent tube on the other side of the recession shown in the illustration.

  3. INSTALL FUEL TANK SUCTION TUBE GASKET


    1. A0118OW

      Install a new gasket to the fuel tank.

  4. INSTALL FUEL SUCTION TUBE ASSEMBLY


    1. A011B7Z

      Line up the pipe and connector and push them together until a "click" sound is heard.

      Note


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

      • After connecting the pipe and connector, check that the pipe and connector are securely connected by pulling on them.

    2. Install the fuel suction tube assembly to the fuel tank.

  5. INSTALL FUEL PUMP GAUGE RETAINER


    1. A011ASBE01
      Text in Illustration
      *1 Cutout

      Align the protrusion of the fuel suction tube assembly with the cutouts of the fuel tank.

      Note

      Ensure that the fuel suction tube gasket is in the correct position.

    2. While holding the fuel suction tube assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

      Note

      Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.

    3. A011AHYE01

      Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

      Note

      Do not use any tools other than SST.

      Tech Tips


      • Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.

      • Align the ribs of the fuel pump gauge retainer with the tips of SST.

    4. A01175BE01

      Using SST, align the marks on the fuel tank and fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

  6. INSTALL FUEL TANK SUCTION TUBE GASKET


    1. A0118E2

      Install a new gasket to the fuel tank.

  7. INSTALL FUEL TANK VENT TUBE ASSEMBLY


    1. A011BVJ

      Engage the 2 claws and connect the fuel tank vent tube sub-assembly to the fuel tank vent tube assembly.

    2. A0118E0E01
      Text in Illustration
      *1 Arrows

      Rotate the fuel tank vent tube in the direction shown by the arrows, insert the sender gauge in the direction of the fuel tank gauge shown by the arrows, and then install the fuel tank vent tube assembly into the fuel tank.

      Note

      Do not bend the sender gauge arm.

  8. INSTALL FUEL PUMP GAUGE RETAINER


    1. A0118UDE01
      Text in Illustration
      *1 Cutout

      Align the protrusion of the fuel tank vent tube assembly with the cutouts of the fuel tank.

      Note

      Ensure that the fuel suction tube gasket is in the correct position.

    2. While holding the fuel tank vent tube assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

      Note

      Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.

    3. A0117GGE01

      Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

      Note

      Do not use any tools other than SST.

      Tech Tips


      • Hold the fuel tank vent tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.

      • Align the ribs of the fuel pump gauge retainer with the tips of SST.

    4. A0118JDE01

      Using SST, align the marks on the fuel tank and fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

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


    1. A011BT7E01

      Connect the No. 1 fuel evaporation tube to the fuel suction tube and fuel tank vent tube assemblies and lock them by pushing in the retainers.

      Note


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

      • Check that the No. 1 fuel evaporation tube is inserted securely.

      • After installing the retainer, check that the No. 1 fuel evaporation tube is securely connected by pulling on it.

    2. Engage the 3 clamps and install the No. 1 fuel evaporation tube to the fuel tank.

  10. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A0119WX
      Text in Illustration
      *1 Yellow mark

      Install the No. 1 charcoal canister outlet hose onto the fuel tank vent tube assembly.

      Note

      Install the No. 1 charcoal canister outlet hose with its yellow mark toward the rear of the vehicle.

    2. Clamp the No. 1 charcoal canister outlet hose.

  11. INSTALL FUEL TANK WIRE


    1. A0119C1

      Install the fuel hose clamp to the fuel tank wire.

    2. A0117LF

      Connect the fuel tank wire connector to the fuel tank vent tube assembly.

    3. Engage the 3 clamps and install the fuel tank wire to the fuel tank.

      Tech Tips

      After connecting the fuel tank wire connector, check that the fuel tank wire is inserted securely.

  12. INSTALL FUEL RETURN TUBE SUB-ASSEMBLY


    1. A01178PE01

      Insert the fuel tank return tube into the fuel suction tube assembly plug and secure it with the tube joint clip.

      Note


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

      • Check that the fuel return tube is inserted securely.

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

      • After installing the tube joint clip, check that the fuel tank return tube is securely connected by pulling on it.

    2. A0117OK

      Engage the clamp and install the fuel tank return tube to the fuel tank.

  13. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01184BE01

      Insert the fuel tank main tube into the fuel suction tube assembly plug and secure it with the tube joint clip.

      Note


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

      • Check that the fuel tank main tube is inserted securely.

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

      • After installing the tube joint clip, check that the fuel tank main tube is securely connected by pulling on it.

    2. A011A8W

      Engage the clamp and install the fuel tank main tube to the fuel tank.

  14. INSTALL FUEL TANK CUSHION


    1. A0117F9E01
      Text in Illustration
      *1 No. 1 fuel tank cushion
      *2 No. 2 fuel tank cushion

      Install the No. 1 fuel tank cushions and the No. 2 fuel tank cushions at the locations indicated in the illustration.

  15. INSTALL FUEL TANK ASSEMBLY


    1. A011ART

      Clean and degrease the bolt holes.

    2. Set the fuel tank on the engine lifter.

    3. Slowly raise the engine lifter and install the fuel tank onto the vehicle.

      Note

      Make sure that the fuel tank does not fall.

    4. A011BM1E01

      Tighten the 4 bolts in the sequence shown in the illustration, and secure the 2 fuel tank bands and the fuel tank.

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

  16. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY


    1. A011BTT

      Connect the fuel return tube sub-assembly.

  17. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0119ZWE01

      Line up the pipe and connector and push them together until a "click" sound is heard.

    2. Push the checker into lock it.

      Note


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

      • Check that the fuel tank main tube is inserted securely.

      • After installing the checker, check that the fuel tank main tube is securely connected by pulling on it.

  18. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY


    1. A0119UEE01

      Connect the inlet tube to the fuel tank assembly and lock it by pushing in the retainer.

      Note


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

      • Check that the inlet tube is inserted securely.

      • After installing the retainer, check that the inlet tube is securely connected by pulling on it.

      Tech Tips


      • Insert the inlet tube until a "click" sound is heard.

      • The quick connector cannot be locked when the tube is not inserted securely.

    2. A011748E01

      Connect the fuel tank breather tube to the fuel tank assembly and lock it by pushing in the retainer.

      Note


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

      • Check that the breather tube is inserted securely.

      • After installing the retainer, check that the breather tube is securely connected by pulling on it.

      Tech Tips

      The quick connector cannot be locked when the tube is not inserted securely.

  19. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A01178LE01
      Text in Illustration
      *1 Yellow mark

      Connect the No. 1 charcoal canister outlet hose.

      Note


      • Install the No. 1 charcoal canister outlet hose with its yellow mark toward the rear of the vehicle.

      • After connecting the fuel tank breather tube and No. 1 charcoal canister outlet hose, check that the evaporation vent tube clamp is securely connected by pulling on it.

  20. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    1. A0119VV

      Engage the claw and install the No. 1 fuel tank protector with the 2 clips and 4 nuts.

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

  21. CONNECT FUEL TANK WIRE


    1. A011BQ7

      Pull the fuel tank wire through the floor, install the grommet in the floor, and connect the fuel tank wire connector.

  22. ADD FUEL


    1. Open the fuel tank cap to add fuel.

  23. BLEED AIR FROM FUEL SYSTEM

    Click here

  24. INSPECT FOR FUEL LEAK


    1. Connect an intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

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

    5. Perform the Active Test.

      Intelligent Tester Display Test Details Control Range Diagnostic Notes
      Test the Fuel Leak Pressurize common rail internal fuel pressure, and check for fuel leaks Stop/Start

      Perform inspection of the high pressure fuel system.

      Test is possible when the following conditions are met:


      • Warmed up engine.

      • Vehicle is stopped.

      • Battery voltage is 12 V or more.

      • PM regeneration is not operating.

      • Engine speed is less than 4000 rpm.

      Results of real-vehicle check:


      • Engine Speed: 2702 rpm


      • Fuel Pressure: 108570 kPa


      • Target Common Rail Pressure: 105500 kPa


      • Target Pump SCV Current: 1.2 A


      • MAP: 127 kPa


      • MAF: 28 g/sec.