FUEL TANK INSTALLATION

PROCEDURE

  1. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A176177C01

      *1

      Fuel Tank Main Tube Sub-assembly

      Install the fuel tank main tube sub-assembly to the fuel tank assembly.

  2. INSTALL FUEL RETURN TUBE SUB-ASSEMBLY

    1. A176176C01

      *1

      Fuel Return Tube Sub-assembly

      Install the fuel return tube sub-assembly to the fuel tank assembly.

  3. INSTALL NO. 2 FUEL TANK CUSHION (w/ No. 2 Fuel Tank Cushion)

    1. A255970C01

      *1

      No. 2 Fuel Tank Cushion

      Install a new No. 2 fuel tank cushion as shown in the illustration.

  4. INSTALL NO. 1 FUEL TANK CUSHION

    1. A255969C01

      *1

      No. 1 Fuel Tank Cushion

      Install a new No. 1 fuel tank cushion as shown in the illustration.

  5. INSTALL FUEL TANK ASSEMBLY

    1. Support the fuel tank assembly using an engine lifter.

    2. Raise the engine lifter, then 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. Temporarily install the fuel tank assembly with the 4 bolts.

    4. A161755N04

      Tighten the fuel tank assembly with the 4 bolts in the order shown in the illustration.

      39.2 N*m

      400 kgf*cm

      29 ft.*lbf

    5. Connect the parking brake cable assembly with the 2 bolts.

      6.0 N*m

      61 kgf*cm

      53 in.*lbf

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A296060C02

      *a

      Retainer

      *b

      Fuel Tube Connector

      *c

      Fuel Pipe

      *d

      O-ring

      V100135

      Push

      V100136

      Push up

      Push in the fuel tube connector to the fuel pipe and push up the retainer so that the claws engage.

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

      • After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

  7. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY

    1. A296061C02

      *a

      Retainer

      *b

      Fuel Tube Connector

      *c

      Fuel Pipe

      *d

      O-ring

      *e

      Nylon Tube

      V100135

      Push

      V100136

      Push up

      Push in the fuel tube connector to the fuel pipe and push up the retainer so that the claws engage.

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

      • After connecting the fuel tube connector, check that the fuel tube connector is securely connected by pulling on the fuel tube connector.

  8. CONNECT FUEL TANK TO FILLER PIPE HOSE

    1. A159053C01

      *a

      Upper

      *b

      180°

      Connect the fuel tank to filler pipe hose to the fuel tank assembly, and tighten the clamp as shown in the illustration.

      Note:

      Be careful of the installation angle of the clamp.

  9. CONNECT FUEL TANK BREATHER TUBE

    1. A296059C01

      *1

      Fuel Tank Breather Tube

      *2

      Evaporation Vent Tube Clamp

      *a

      Upper

      *b

      20°

      *c

      180°(Clamp Area)

      Connect the fuel tank breather tube to the fuel tank filler pipe sub-assembly, and tighten the clamp as shown in the illustration.

      Note:

      After connecting the fuel tank breather tube, check that the evaporation vent tube clamp is securely connected to the fuel tank assembly.

  10. INSTALL NO. 1 FUEL TANK PROTECTOR

    1. A161754N03

      Temporarily install the No. 1 fuel tank protector with the 3 bolts and nut.

    2. Tighten the No. 1 fuel tank protector with the 3 bolts and nut in the order shown in the illustration.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  11. INSTALL CENTER EXHAUST PIPE ASSEMBLY

  12. INSTALL REAR NO. 1 FLOOR UNDER COVER

    1. A152321

      Install the rear No. 1 floor under cover with the grommet.

    2. Install the 4 clips and nut.

  13. INSTALL REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

  14. INSTALL REAR FLOOR SIDE MEMBER COVER LH (w/ Cover)

  15. INSTALL REAR FLOOR SIDE MEMBER COVER RH (w/ Cover)

  16. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY (except Sedan)

  17. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY (for Sedan)

  18. ADD FUEL

  19. INSPECT FOR EXHAUST GAS LEAK