Fuel Tank Installation

Install the 3 fuel tank protector cushions as shown in the illustration.

Attach the 2 claws to install the No. 2 fuel tank protector.

Install the fuel tank to filler pipe hose to the fuel tank.

Install the fuel tank breather hose to the fuel tank.

Apply a light coat of gasoline or grease to a new gasket and install the gasket to the fuel tank.

Install the fuel tank vent tube to the fuel tank.

NOTICE:

Be careful not to bend the arm of the fuel sender gauge.

Set the fuel pump gauge retainer on the fuel tank. While holding the fuel tank vent tube, tighten the fuel pump gauge retainer one complete turn by hand.

Temporarily install SST (plate and 4 claws) to the fuel pump gauge retainer.

SST

09808-14030

HINT:

1. Hold the fuel tank vent tube sub-assembly upright by hand to make that the gasket is not moved out of position.
   
2. Be sure to use 4 SST (claws) as shown in the illustration.
   
3. Engage SST (claws) securely with the fuel pump gauge retainer ribs to secure SST.
   

While pressing SST (claws) to the fuel pump gauge retainer ribs securely, install the 4 bolts.

HINT:

Install SST while pressing SST (claws) against the fuel pump gauge retainer (toward the center of SST).

Install SST (handle).

Using SST, tighten the fuel pump gauge retainer until the mark on the fuel pump gauge retainer aligns with mark A on the fuel tank, as shown in the illustration.

SST

09808-14030

NOTICE:

1. Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
   
2. Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.
   
3. Make sure to rotate SST (handle) horizontally. If SST (handle) is rotated at an angle, SST may come off.
   
4. Do not spin SST too fast or use an impact wrench as this may result in damage to components.
   
5. If SST comes off of the fuel pump gauge retainer, loosen SST (bolts) and reinstall SST.
   

HINT:

1. If the alignment is difficult, make sure the mark on the fuel pump gauge retainer is within range B on the fuel tank.
   
2. Lightly press down on SST to prevent it from separating from the fuel pump gauge retainer. While pressing SST, rotate the handle slowly to tighten the fuel pump gauge retainer.
   
3. The tips of SST (claws) can be fitted onto the ribs of the fuel pump gauge retainer.
   

Install the fuel tank return tube and fuel tank main tube to the fuel tank.

Install the 2 fuel tank tubes with the 2 tube joint clips.

NOTICE:

1. Check that there are no scratches or foreign objects on the connecting parts.
   
2. Check that the fuel tube joints are inserted securely.
   
3. Check that the tube joint clips are on the collars of the fuel tube joints.
   
4. After installing the tube joint clips, check that the fuel tube joints cannot be pulled off.
   

Install the No. 1 fuel evaporation tube to the fuel tank.

Install 2 new fuel tank cushions.

Text in Illustration

*1	Clip
	Fuel Tank Cushion

Install the clip to the cushion on the front side.

HINT:

Install only 1 clip so that the cushion can be folded back and the wire harness can be installed when the fuel tank assembly is installed to the vehicle.

Install the No. 1 fuel tank heat insulator with the 4 clips and nut.

Set the fuel tank on an engine lifter and raise the fuel tank.

NOTICE:

Do not allow the fuel tank to contact the vehicle, especially the differential.

Fold back the 2 cushions.

Attach the wire harness to the 6 wire harness clips and connect the fuel sender gauge connector.

NOTICE:

Be careful not to cut the wiring.

Install the clip.

Install the 2 fuel tank bands with the 2 pins and 2 clips.

Connect the 2 fuel tank bands with the 2 bolts.

Torque:

61 N*m{622 kgf*cm, 45 ft.*lbf}

Connect the fuel tank to filler pipe hose to the fuel tank filler pipe.

Connect the fuel tank breather hose to the fuel tank filler pipe.

Connect the fuel tank main tube and fuel tank return tube.

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

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}