Fuel Tank Installation

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

Install the fuel gauge tube to the fuel tank.

NOTICE:

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

Put the retainer on the fuel tank. While holding the pump and gauge tube, tighten the retainer 1 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.
   

Install 3 new fuel tank cushions.

Install the heat insulator with 5 new clips.

Set the fuel tank on a mission jack.

Raise the mission jack.

Fold back the 2 cushion rubbers.

Connect the 4 harness clips and fuel pump connector to the fuel tank.

NOTICE:

Be careful not to cut the wirings.

Install the 3 fuel tank bands with the 3 pins and 3 clips.

Connect the 3 fuel tank bands with the 3 bolts.

Torque:

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

Install the filler pipe with the bolt and nut.

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.

for Unleaded Gasoline Specification Vehicle:
Connect the vent line hose.

Install the tube clamp to the fuel tube.

Install the fuel tank protector with the 4 nuts.

Torque:

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

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. Select the Active Test and 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.
   If there are fuel leaks, repair or replace parts as necessary.