FUEL TANK INSTALLATION

INSTALL FUEL TANK COVER VENT CASE SUB-ASSEMBLY
1. Install 2 new fuel tank cover vent case sub-assemblies as shown in the illustration.
INSTALL NO. 1 FUEL TANK CUSHION
1. Text in Illustration
  
  *1 No. 1 Fuel Tank Cushion
  
  Install 3 new No. 1 fuel tank cushions as shown in the illustration.
INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE
1. Install the hose clamp and the No. 1 charcoal canister outlet hose to the fuel tank.
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 }

Text in Illustration
*1	No. 1 Fuel Tank Cushion

CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Text in Illustration
*1	Fuel Tube Connector 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 fuel tube connector cover of the fuel tube connector.

Note

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

CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY

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.

CONNECT FUEL TANK TO FILLER PIPE HOSE
1. Text in Illustration
  
  *a Upper Side
  
  *b 120°
  
  Connect the fuel tank to filler pipe hose to the fuel tank as shown in the illustration, then fit the hose with the clamp.
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.
INSTALL NO. 1 FUEL TANK PROTECTOR
1. Install the No. 1 fuel tank protector with the 2 bolts and nut.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL REAR FLOOR SIDE MEMBER COVER LH
1. Install the rear floor side member cover LH with the 2 clips.
2. Install the 2 bolts and nut.

Text in Illustration
*a	Upper Side
*b	120°

INSTALL TAIL EXHAUST PIPE ASSEMBLY

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

Minimum 38.5 mm (1.52 in.)

Tech Tips

If the free length is less than minimum, replace the compression spring.
Fully insert a new gasket to the front exhaust pipe assembly.

Text in Illustration
*1	Front Exhaust Pipe Assembly
*2	Gasket
*3	Wooden Block

Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the front exhaust pipe assembly.

Note

Be careful with the installation direction of the gasket.
Do not reuse the gasket.
Do not damage the gasket.
Do not push in the gasket by using the exhaust pipe when connecting it.

Connect the tail exhaust pipe assembly to the 3 exhaust pipe supports.
Install the tail exhaust pipe assembly with the 2 bolts and 2 compression springs.

Torque:

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

ADD FUEL
INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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INSPECT FOR EXHAUST GAS LEAK