FUEL TANK INSTALLATION

PROCEDURE


  1. INSTALL FUEL TANK TO FILLER PIPE HOSE


    1. B005YNSE02
      Text in Illustration
      *a Up
      *b 90°
      *c

      60°

      (Clip Area)

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

  2. INSTALL CHARCOAL CANISTER OUTLET HOSE


    1. Connect the No. 1 fuel tube clamp to the fuel tank breather tube.

    2. Install the charcoal canister outlet hose to the No. 1 fuel tube clamp.

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


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

  4. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


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

  5. INSTALL NO. 1 FUEL TANK CUSHION


    1. B005YCRE02
      Text in Illustration
      *1 No. 1 Fuel Tank Cushion
      *2 No. 2 Fuel Tank Cushion

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

  6. INSTALL NO. 2 FUEL TANK CUSHION


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

  7. INSTALL FUEL TANK ASSEMBLY


    1. Support the fuel tank using an engine lifter.

    2. Raise the engine lifter, then install the fuel tank to the vehicle.

      Note


      • Do not drop the fuel tank.

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

    3. Tighten the 4 set bolts of the 2 fuel tank bands.

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

  8. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Align the quick connector with the pipe, connect the quick connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer.

      B005YGUE01
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Fuel Tank Main Tube
      *4 Fuel Pipe
      *5 O-ring
      B005XEC Push

      Note


      • Check that there are no scratches or foreign matter around the connected part 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 the fuel tube connector.

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


    1. B005ZGUE01
      Text in Illustration
      *a Up
      *b 90°

      Connect the No. 1 fuel evaporation tube sub-assembly, then fit it with the clip as shown in the illustration.

      Note

      Check that there is no damage or foreign matter around the connecting parts of the No. 1 fuel evaporation tube sub-assembly and fuel pipe before performing this work.

  10. CONNECT FUEL TANK TO FILLER PIPE HOSE


    1. B005XQSE01
      Text in Illustration
      *a Up
      *b 2.5 to 5.5 mm (0.0984 to 0.217 in.)
      *c 90°

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

  11. REMOVE FUEL TANK BREATHER TUBE


    1. B005YUWE02
      Text in Illustration
      *1 Fuel Tank Breather Tube
      *2 Charcoal Canister Outlet Hose
      *3 Breather Tube Clamp
      *a Up
      *b 60°
      *c 30°

      Connect the fuel tank breather tube to the fuel tank as shown in the illustration, then fit it with the clamp.

  12. CONNECT CHARCOAL CANISTER OUTLET HOSE


    1. Connect the charcoal canister outlet hose.

    2. Connect the charcoal canister outlet hose and fuel tank breather tube to the breather tube clamp.

  13. INSTALL NO. 1 FUEL TANK PROTECTOR


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

  14. INSTALL REAR SUSPENSION BRACE SUB-ASSEMBLY

    Click here

  15. INSTALL REAR FLOOR SIDE MEMBER COVER RH

    Click here

  16. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  17. INSTALL FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Click here

  18. ADD FUEL

  19. INSPECT FOR EXHAUST GAS LEAK