FUEL TANK INSTALLATION

REMOVE FUEL TANK ASSEMBLY
1. Set the fuel tank on a transmission jack.
2. Lift up the transmission jack.
  
  Note
  
  Be careful not to cut the wiring.
3. Install the fuel tank with the 2 fuel tank bands and 4 bolts.
  
  Torque:
  
  39 N*m { 400 kgf*cm, 29 ft.*lbf }
CONNECT FUEL HOSE
1. Connect the No. 1 charcoal canister outlet hose.
2. Connect the fuel tank vent hose as shown in the illustration.
  
  Note
  
  Be sure to tighten the hose clamp so that it is at the correct angle.
3. Connect the fuel tank to filler pipe hose as shown in the illustration.
  
  Note
  
  Be sure to tighten the hose clamp so that it is at the correct angle.

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Text in Illustration
*1	O-Ring
*2	Fuel Pipe
*3	Retainer
*4	Nylon Tube

Connect the fuel tank main tube.

Tech Tips

Push the parts together firmly until a "click" sound is heard.

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.

CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

Text in Illustration
*1	O-Ring
*2	Fuel Pipe
*3	Retainer
*4	Nylon Tube

Push the tube connector onto the fuel pipe and install the retainer.

Note

Check if there is any damage or foreign objects on the connection part of the fuel pipe.
After connecting, check if the fuel pipe and connector are securely connected by pulling on them.

CONNECT PARKING BRAKE CABLE
1. Connect the parking brake cable with the 2 bolts and 2 nuts.
  
  Torque:
  
  for nut
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
  
  for bolt
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL NO. 1 FUEL TANK PROTECTOR
1. Install the No. 1 fuel tank protector with the 3 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
2. Connect the fuel pump connector.
INSTALL TAILPIPE ASSEMBLY
1. Using a vernier caliper, measure the free length of the compression springs.
  
  Minimum free length
  
  38.5 mm (1.52 in.)
  
  If the free length is less than the minimum, replace the compression spring.
2. Text in Illustration
  
  *1 Gasket
  
  *2 Wooden Block
  
  Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the front exhaust pipe assembly.
  Note
  
  Be sure to install the gasket so that it faces the correct direction.
  
  Do not reuse the gasket.
  
  Do not damage the gasket.
  
  When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.
3. Install the 4 exhaust pipe supports, and then install the tailpipe assembly with the 2 bolts and 2 compression springs.
  
  Torque:
  
  43 N*m { 439 kgf*cm, 32 ft.*lbf }
ADD FUEL
INSTALL FUEL TANK CAP ASSEMBLY
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSPECT FUEL LEAK
1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.
  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch to ON, and push the intelligent tester main switch 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.
  5. Turn the ignition switch off.
  6. Disconnect the intelligent tester from the DLC3.
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Install the rear floor service hole cover with new butyl tape.
INSTALL NO. 1 QUARTER WHEEL HOUSE GUSSET SUB-ASSEMBLY
1. Align the 2 claws with the 2 gusset positioning holes and install the gusset with the 6 bolts.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
INSTALL REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Sedan)
1. Attach the 2 rear hooks of the seat cushion to the seatback.
2. Attach the 2 front hooks to install the seat cushion.
3. Confirm that the seat cushion is firmly installed.
  
  Note
  
  When installing the seat cushion, make sure the seat belt buckle is not under the seat cushion.
INSTALL REAR BENCH TYPE SEAT CUSHION ASSEMBLY (for Wagon)
1. Attach the 2 rear hooks of the seat cushion to the seatback.
2. Attach the 2 front hooks to install the seat cushion.
3. Confirm that the seat cushion is firmly installed.
  
  Note
  
  When installing the seat cushion, make sure the seat belt buckle is not under the seat cushion.

Text in Illustration
*1	Gasket
*2	Wooden Block