FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 FUEL TANK CUSHION


    1. Install 10 new No. 1 fuel tank cushions to the fuel tank assembly.

  2. INSTALL NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Install the fuel filter to the No. 2 fuel tank main tube sub-assembly.

    2. Install the No. 2 fuel tank main tube sub-assembly to the fuel tank assembly.

  3. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. Install the fuel tank to filler pipe hose to the fuel tank assembly with the clamp.

    2. Tighten the hose clamp bolt.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  4. INSTALL FUEL TANK ASSEMBLY


    1. A004HPP

      Inspect the fuel tank cover.

      Tech Tips

      The fuel tank cover is used as a base when attaching the fuel tank assembly, so inspect for any deformation, cracking, or other damage. If any faults are found, replace with a new one.

    2. Hold the fuel tank assembly with an engine lifter.

    3. Temporarily install the fuel tank assembly to the body with the 2 No. 1 fuel tank bands and 4 bolts.

    4. A004HTB

      Adjust the position of the fuel tank assembly to achieve the required separation between the front edge of the fuel tank cover and the holes used for fixing the parking brake cable bracket in place.

      Standard
      42 to 44 mm (1.6535 to 1.7323 in.)
    5. A004HMI

      Adjust the position of the fuel tank assembly to achieve the required difference in clearance between the left and right sides of the fuel tank assembly and the body.

      Standard
      Below 2 mm (Below 0.0787 in.)
    6. A004JRNE01

      Tighten the 4 bolts in the order shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  5. CONNECT NO. 6 FUEL TANK BREATHER TUBE (for Clamp Type)


    1. Connect the No. 6 fuel tank breather tube with the clamp.

  6. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY (for Metal Type)


    1. Connect the fuel tank vent hose sub-assembly.

  7. CONNECT FUEL TANK TO FILLER PIPE HOSE (for Clamp Type)


    1. Connect the fuel tank to filler pipe hose to the fuel tank filler pipe sub-assembly with the clamp.

    2. Tighten the hose clamp bolt.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  8. INSTALL CHARCOAL CANISTER ASSEMBLY (for Metal Type)


    1. A004KBEE03

      Connect the quick connector as indicated by the arrows in the order shown in the illustration.

  9. CONNECT FUEL TANK VENT HOSE SUB-ASSEMBLY (for Metal Type)


    1. Engage the clamp to install the tube.

    2. Connect the fuel tank vent hose sub-assembly with the clamp.

  10. CONNECT FUEL TANK TO FILLER PIPE HOSE (for Metal Type)


    1. Connect the fuel tank to filler pipe hose to the fuel tank filler pipe sub-assembly with the clamp.

    2. Tighten the hose clamp bolt.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  11. INSTALL NO. 3 PARKING BRAKE CABLE ASSEMBLY

    Click here

  12. INSTALL NO. 2 PARKING BRAKE CABLE ASSEMBLY

    Click here

  13. INSTALL NO. 2 FUEL TANK PROTECTOR (for Clamp Type)


    1. Install the No. 2 fuel tank protector with 2 new nuts and 2 clips.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  14. INSTALL NO. 1 FUEL TANK PROTECTOR (for Clamp Type)


    1. Install the No. 1 fuel tank protector with 2 new nuts and 2 clips.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  15. INSTALL NO. 3 FUEL TANK PROTECTOR (for Metal Type)


    1. Install the No. 3 fuel tank protector with a new nut and 2 clips.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  16. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY

    Click here

  17. INSTALL FUEL TANK RETURN TUBE

    Click here

  18. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

    Click here

  19. ADD FUEL

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

  21. INSPECT FOR FUEL LEAK

    Click here

  22. INSTALL NO. 2 REAR FLOOR SERVICE HOLE COVER

    Click here

  23. INSTALL REAR FLOOR SERVICE HOLE COVER

    Click here

  24. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY LH

    Click here

  25. INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSEMBLY RH

    Click here