FUEL TANK INSTALLATION


  1. INSTALL FUEL TANK COVER VENT CASE SUB-ASSEMBLY


    1. A01JCIG

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

  2. INSTALL NO. 1 FUEL TANK CUSHION


    1. A01J9OCE01
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion

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

  3. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. Install the hose clamp and the 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. 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. Tighten the 4 set bolts of the 2 fuel tank bands.

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

    4. 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. A01JB94E07
      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 pipe, push the fuel tube connector in until the retainer makes a "click" sound, then lock the cover of the connector.

      Note


      • Check that there are no scratches or foreign matter around the connected parts of the fuel tube connector and pipe before starting this step.

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

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


    1. A01JBV1E06
      Text in Illustration
      *1 Rubber Hose
      *2 O-ring
      *3 Fuel Pipe
      *4 Retainer
      *a Push

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

      Note


      • Check if there is any damage or foreign matter on the connected parts of the fuel pipe.

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

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A01JBKKE02
      Text in Illustration
      *a 120°
      *b Upper Side

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

  8. CONNECT FUEL TANK BREATHER TUBE


    1. 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. 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 and clip.

      A01JD65
      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  11. INSTALL REAR FLOOR SIDE MEMBER COVER LH


    1. A01J8O5

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

  12. INSTALL REAR FLOOR SIDE MEMBER COVER RH


    1. A01JA88

      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 ASSEMBLY WITH PUMP AND GAUGE

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