FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL CHARCOAL CANISTER OUTLET HOSE


    1. Engage the 2 clamps to install the charcoal canister outlet hose to the fuel tank assembly.

  2. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Engage the 3 clamps to install the fuel tank main tube sub-assembly to the fuel tank assembly.

  3. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Engage the 4 clamps to install the No. 1 fuel evaporation tube sub-assembly to the fuel tank assembly.

  4. INSTALL NO. 1 FUEL TANK CUSHION


    1. Install the 2 new No. 1 fuel tank cushions to the fuel tank assembly.

  5. INSTALL FUEL TANK ASSEMBLY

    CAUTION:

    The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

    B008K75

    1. Set the fuel tank assembly on an engine lifter.

      Note

      Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

    2. Using the engine lifter, slowly raise the fuel tank assembly, and then install the fuel tank assembly with the 2 fuel tank band sub-assemblies with the 4 bolts.

    3. A001TW7N01

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

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

      Note


      • Be careful not to drop the fuel tank assembly.

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

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A001TH2

      Connect the fuel tank main tube sub-assembly to the fuel pipe.

      Click here

  7. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A001WYB

      Connect the No. 1 fuel evaporation tube sub-assembly to the fuel pipe and slide the clip to secure it.

      Click here

  8. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. A001W7NC01
      *a 120°
      *b Up
      *c Paint Mark (Fuel Tank To Filler Pipe Hose)
      *d Protrusion (Fuel Tank Assembly)

      Connect the fuel tank to filler pipe hose to the fuel tank assembly and tighten the clamp to secure it.

      Tech Tips

      Make sure the clamp and fuel tank to filler pipe hose are positioned within the area shown in the illustration.

  9. CONNECT FUEL TANK BREATHER TUBE


    1. B008KYI

      Connect the fuel tank breather tube to the fuel tank filler pipe sub-assembly.

      Click here

  10. CONNECT CHARCOAL CANISTER OUTLET HOSE


    1. A001SGSC01
      *a 120°
      *b Paint Mark

      Connect the charcoal canister outlet hose to the fuel tank filler pipe sub-assembly and slide the hose clip to secure it.

      Note

      Perform the installation with the charcoal canister outlet hose clip at the correct angle.

  11. INSTALL NO. 1 FUEL TANK PROTECTOR


    1. Install the No. 1 fuel tank protector to the fuel tank assembly with the nut and 4 clips.

      Torque:
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

  12. INSTALL TAIL EXHAUST PIPE ASSEMBLY

    Click here

  13. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  14. ADD FUEL