FUEL TANK INSTALLATION

PROCEDURE

1. INSTALL FUEL TANK TO FILLER PIPE HOSE

   1. 

      *1	Fuel Tank Side Mark
      *2	Hose Side Mark

      Install the fuel tank to filler pipe hose to the fuel tank.

      Tip:

      Align the fuel tank side mark with the hose side mark when installing the hose.

2. INSTALL NO. 3 FUEL TANK PROTECTOR

   1. Install the No. 3 fuel tank protector and attach the 4 clamps.

   2. Install the 2 bolts.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

3. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

   1. Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank.

   2. 

      *1	Protrusion
      *2	Groove

      Install the fuel suction with pump and gauge tube into the fuel tank.

      Tip:

      Align the protrusion of the fuel suction with pump and gauge tube with the groove of the fuel tank.

      Note:

      Be careful not to bend the arm of the fuel sender gauge.

   3. Put a new retainer on the fuel tank. While holding the fuel suction with pump and gauge tube, tighten the retainer one complete turn by hand.

      

      *1	Start Mark (Fuel Tank Side)
      *2	Start Mark (Retainer Side)

      Tip:

      Make sure the start marks on the retainer and fuel tank are aligned and then tighten the retainer.

   4. 

      *1	Fuel Tank Side Mark
      *2	Retainer Side Mark

      Using SST, tighten the retainer until the mark on the retainer is within range A on the fuel tank as shown in the illustration.

      09808-14020

      Tip:

      Fit the tips of SST onto the ribs of the retainer.

4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY AND FUEL RETURN TUBE SUB-ASSEMBLY

   1. 

      Install the fuel tank main tube and fuel return tube with the 2 fuel tube joint clips.

      Note:

      • 

        *1	Fuel Tube Joint
        *2	O-ring
        *3	Fuel Tube
        *4	Fuel Tube Joint Clip
        *5	CORRECT
        *6	INCORRECT

        Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tube joints are inserted securely.

      • Check that the fuel tube joint clips are on the collars of the fuel tube joints.

      • After installing the fuel tube joint clips, check that the fuel tube joints cannot be pulled off.

   2. Install the fuel tank main tube and fuel return tube to the fuel tank.

5. INSTALL FUEL TANK CUSHION

   1. Install 3 new fuel tank cushions to the fuel tank.

6. INSTALL FUEL TANK SUB-ASSEMBLY

   1. Set the fuel tank on a transmission jack and lift up the transmission jack.

   2. Install the 2 fuel tank bands with the 2 pins and 2 clips.

   3. Connect the 2 fuel tank bands with the 2 bolts.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

7. CONNECT FUEL TANK TO FILLER PIPE HOSE

   1. Connect the fuel tank to filler pipe hose to the filler pipe.

8. CONNECT FUEL CUT OFF TUBE

   1. Connect the fuel cut off tube (Click here).

9. CONNECT FUEL TANK BREATHER TUBE SUB-ASSEMBLY

   1. Connect the fuel tank breather tube (Click here).

10. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY

    1. Connect the fuel return tube (Click here).

11. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. Connect the fuel tank main tube (Click here).

12. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

    1. Install the No. 1 fuel tank protector with the 6 bolts.

       20 N*m

       204 kgf*cm

       15 ft.*lbf

13. INSTALL REAR FLOOR SERVICE HOLE COVER

    1. Connect the fuel pump and fuel sender gauge connector.

    2. Install the rear floor service hole cover with the 3 screws.

14. INSTALL REAR SEAT ASSEMBLY LH

    1. for 60/40 Split Slide Walk-in Seat Type LH Side:

       Install the rear seat assembly LH (Click here).

15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click hereClick hereClick hereClick here).

16. INSPECT FOR FUEL LEAK

    Click here