Fuel Tank Installation

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

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

SST

09808-14020(09808-01410,09808-01420,09808-01430)

HINT:

1. If the alignment is difficult, make sure the mark on the retainer is within range B on the fuel tank.
   
2. Fit the tips of SST onto the ribs of the retainer.
   

Install the 2 fuel pump 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 joint is 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 have not been pulled off.
   
5. Be careful not to damage any clips. If a clip is damaged, replace it.
   

Install 2 new fuel tank cushions.

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 heat insulator with 4 new clips and the nut.

Set the fuel tank on a mission jack.

Raise the mission jack.

Fold back the 2 cushion rubbers.

Connect the 6 harness clips and fuel pump connector to the fuel tank.

NOTICE:

Be careful not to cut the wirings.

Install the cushion rubber on the front side with the remaining clip.

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

Connect the 2 fuel tank bands with the 2 bolts.

Torque:

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

Install the filler pipe with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

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

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

Connect the return tube connector to the pipe. Then connect the main tube connector to the pipe. Push the 2 parts together firmly until a "click" sound is heard.

NOTICE:

Check that the connectors and pipes are securely connected by trying to pull them apart.

Install the tube clamp to the fuel tube.

Connect the intelligent tester to the DLC3.

1. Turn the ignition switch ON.
   

   NOTICE:

   Do not start the engine.

2. Push the intelligent tester main switch ON.
   

3. To perform the Active Test, enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
   

Check for fuel leaks.

1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.