FUEL TANK INSTALLATION

PROCEDURE

1. INSTALL FUEL TANK RETURN TUBE SUB-ASSEMBLY

   1. Attach the fuel tank return tube sub-assembly to the 3 clamps to install it.

2. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

   1. Attach the fuel tank main tube sub-assembly to the 4 clamps to install it.

3. INSTALL NO. 2 FUEL TANK MAIN TUBE SUB-ASSEMBLY (w/ Combustion Type Power Heater)

4. INSTALL FUEL TANK TO FILLER PIPE HOSE

   1. 

      Install the fuel tank to filler pipe hose to the fuel tank and tighten the hose clamp bolt so that the clamp is as shown in the illustration.

      Table 1. Text in Illustration

      *a

      Top

      Note:

      Be sure to tighten the hose clamp so that it is at the correct angle.

      Tip:

      From the position in the illustration, the hose clamp can also be positioned so that the hose clamp bolt is on the opposite side of the hose with the bolt tip facing upwards.

5. INSTALL NO. 2 FUEL TANK CUSHION

   1. 

      Install 2 new No. 2 fuel tank cushions at the locations shown in the illustration.

6. INSTALL NO. 1 FUEL TANK CUSHION

   1. 

      Install 4 new No. 1 fuel tank cushions at the locations shown in the illustration.

7. INSTALL FUEL TANK ASSEMBLY

   1. Using a engine lifter, support the fuel tank assembly.

   2. Raise the engine lifter and install the fuel tank assembly to the vehicle.

      Note:

      • Do not drop the fuel tank assembly.

      • When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the suspension arm or other surrounding parts.

   3. Install the No. 1 fuel tank band sub-assembly RH and No. 1 fuel tank band sub-assembly LH with the 4 bolts.

      39 N*m

      398 kgf*cm

      29 ft.*lbf

   4. w/ Combustion Type Power Heater:

      Connect the No. 2 fuel tank main tube sub-assembly to the No. 2 fuel main tube and slide the clamp to secure it.

   5. Connect the fuel tank main tube sub-assembly to the fuel main tube (Click here).

   6. Connect the fuel tank return tube sub-assembly to the fuel return tube (Click here).

   7. Connect the parking brake cable with the 2 bolts.

      6.0 N*m

      61 kgf*cm

      53 in.*lbf

   8. 

      Connect the breather hose to the fuel tank filler pipe and tighten the hose clamp bolt so that the clamp is as shown in the illustration.

      Table 2. Text in Illustration

      *a

      Top

      Note:

      Be sure to tighten the hose clamp so that it is at the correct angle.

8. CONNECT FUEL TANK TO FILLER PIPE HOSE

   1. 

      Connect the fuel tank to filler pipe hose to the fuel tank filler pipe and tighten the hose clamp bolt so that the clamp is as shown in the illustration.

      Table 3. Text in Illustration

      *a

      Top

      Note:

      Be sure to tighten the hose clamp so that it is at the correct angle.

9. INSTALL NO. 1 FUEL TANK PROTECTOR

   1. Install the fuel tank protector cushion.

   2. Install the No. 1 fuel tank protector with the 4 clips.

10. INSTALL REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

    1. 

       Attach the clip and install the rear floor side member brace sub-assembly with the 4 bolts.

       54 N*m

       551 kgf*cm

       40 ft.*lbf

       Table 4. Text in Illustration

       *1

       Clip

11. INSTALL REAR FLOOR SIDE MEMBER COVER LH

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

12. INSTALL REAR FLOOR SIDE MEMBER COVER RH

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

13. INSTALL FRONT FLOOR CENTER COVER LH

    1. 

       Attach the grommet and install the front floor center cover LH with the nut.

       Table 5. Text in Illustration

       *1

       Grommet

14. INSTALL FRONT FLOOR CENTER COVER RH

    1. 

       Attach the grommet and install the front floor center cover RH with the nut.

       Table 6. Text in Illustration

       *1

       Grommet

15. ADD FUEL

16. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    (Click hereClick here)

17. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    (Click here)

18. INSPECT FOR FUEL LEAK

    Click hereClick here