FUEL TANK INSTALLATION


  1. INSTALL FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A003ZX6

      Install 2 new fuel tank cover vent case sub-assemblies as shown in the illustration.

  2. INSTALL NO. 1 FUEL TANK CUSHION


    1. A0042DC

      Install 3 new No. 1 fuel tank cushions as shown in the illustration.

  3. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A0041YC

      Install the hose clamp and No. 1 charcoal canister outlet hose to the fuel tank.

  4. INSTALL FUEL TANK ASSEMBLY


    1. Support the fuel tank using an engine lifter.

    2. A0040V4

      Raise the engine lifter, then 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. A0040YE

      Install the 2 fuel tank bands with the 4 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
    4. A0040OK

      Connect the parking brake cable assembly with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  5. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0042YUE07
      Text in Illustration
      *1 Lock Cover
      *2 Retainer
      *3 Nylon Tube
      *4 Fuel Tube Connector
      *5 Fuel Pipe
      *6 O-ring
      *a Push

      Align the fuel tube connector with the fuel pipe, push the fuel tube connector in until the retainer makes a "click" sound, then lock the cover of the fuel tube connector.

      Note


      • Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.

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

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


    1. A0040GTE08
      Text in Illustration
      *1 Rubber Hose
      *2 O-ring
      *3 Fuel Pipe
      *4 Retainer
      *5 Fuel Tube Connector
      *a Push

      Push in the fuel tube connector to the fuel pipe and install the retainer.

      Note


      • Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.

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

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A0041PBE01
      Text in Illustration
      *1 120°
      *2 Upper Side

      Connect the fuel tank to filler pipe hose to the fuel tank as shown in the illustration, then fit it with the clamp.

  8. CONNECT FUEL TANK BREATHER TUBE


    1. A00411V

      Connect the fuel tank breather tube to the fuel tank.

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

      Note

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

  9. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. A0042ZS

      Install the fuel tank protector sub-assembly with the 3 bolts.

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

  10. INSTALL REAR SUSPENSION BRACE SUB-ASSEMBLY


    1. Install the rear suspension brace sub-assembly with the 4 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  11. INSTALL REAR FLOOR SIDE MEMBER COVER LH


    1. Install the rear floor side member cover LH with the nut and 2 bolts.

  12. INSTALL REAR FLOOR SIDE MEMBER COVER RH


    1. Engage the clip to temporarily install the rear floor side member cover RH.

    2. Install the rear floor side member cover RH with the 3 bolts.

  13. ADD FUEL

  14. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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