FUEL TANK INSTALLATION

PROCEDURE

  1. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE

    1. A176169

      Install the No. 1 charcoal canister outlet hose to the fuel tank assembly.

    2. Connect the No. 1 charcoal canister outlet hose with the clamp.

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

    1. A176168C01

      *1

      No. 1 Fuel Evaporation Tube Sub-assembly

      Install the No. 1 fuel evaporation tube sub-assembly to the fuel tank assembly.

  3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A176167C01

      *1

      Fuel Tank Main Tube Sub-assembly

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

      Tip:

      After installing the fuel tank main tube sub-assembly and No. 1 fuel evaporation tube sub-assembly, check that the fuel tank main tube sub-assembly is positioned above the No. 1 fuel evaporation tube sub-assembly.

  4. INSTALL NO. 4 FUEL TANK CUSHION

    1. Install a new No. 4 fuel tank cushion to the fuel tank assembly.

  5. INSTALL NO. 2 FUEL TANK CUSHION

    1. A289964C01

      *1

      No. 1 Fuel Tank Cushion

      *2

      No. 2 Fuel Tank Cushion

      Install 3 new No. 2 fuel tank cushions as shown in the illustration.

  6. INSTALL NO. 1 FUEL TANK CUSHION

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

  7. 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. A161755N03

      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

  8. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

    1. A289978C02

      *a

      Retainer

      *b

      Fuel Tube Connector Cover

      *c

      Fuel Tube Connector

      *d

      Fuel Pipe

      *e

      Nylon Tube

      *f

      O-ring

      Align the fuel tube connector with the pipe, push the fuel tube connector in until the retainer makes a "click" sound, then engage the lock of the fuel tube connector cover.

      Note:

      • Check that there are no scratches or foreign matter around the connecting parts of the fuel tube connector and fuel pipe before starting this step.

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

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

    1. A154751C11

      *a

      Fuel Pipe

      *b

      Rubber Hose

      *c

      Retainer

      *d

      O-ring

      Align the fuel tube connector with the fuel pipe, then push in the fuel tube connector until the retainer makes a "click" sound.

      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 it.

  10. CONNECT FUEL TANK TO FILLER PIPE HOSE

    1. A153002C01

      *a

      Upper

      *b

      180°

      Connect the fuel tank to filler pipe hose to the fuel tank assembly as shown in the illustration, then fit it with the clamp.

  11. CONNECT FUEL TANK BREATHER TUBE

    1. A289979C02

      *1

      No. 1 Charcoal Canister Outlet Hose

      *2

      Fuel Tank Breather Tube

      *3

      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 as shown in the illustration.

  12. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE

    1. Connect the No. 1 charcoal canister outlet hose to the fuel tank filler pipe sub-assembly.

      Note:

      After connecting the breather tube and No. 1 charcoal canister outlet hose, check that the evaporation vent tube clamp is securely connected to the fuel tank assembly.

  13. INSTALL NO. 1 FUEL TANK PROTECTOR

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

    2. A161754N02

      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

  14. INSTALL CENTER EXHAUST PIPE ASSEMBLY

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  15. INSTALL REAR FLOOR SIDE MEMBER BRACE SUB-ASSEMBLY

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  16. INSTALL REAR FLOOR SIDE MEMBER COVER LH

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  17. INSTALL REAR FLOOR SIDE MEMBER COVER RH

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  18. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

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