Fuel Tank Installation

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 it to the fuel tank.

Install the fuel suction with pump and gauge tube to the fuel tank.

NOTICE:

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

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

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

SST

09808-14020

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

Install the No. 1 fuel evaporation tube.

Install 4 new fuel tank cushions.

Install the No. 1 fuel tank protector with the 5 clips and 2 nuts.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Set the fuel tank on a transmission jack 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 4 clamps and connect the fuel pump and sender gauge connector.

NOTICE:

Be careful not to cut the wiring.

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

Attach the breather hose to the 2 clamps.

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

Connect the fuel tank return tube connector to the pipe. Then connect the fuel tank main tube connector to the pipe. Push the 2 tube connectors into the pipe until the tube connector makes a "click" sound.

NOTICE:

1. 
   
2. Check if there is any damage or foreign objects on the connected part of the fuel pipe.
   
3. After connecting, check that the pipe and connector are securely connected by pulling them.
   

Connect the vent line hose to the fuel pipe.

Install the 2 tube clamps 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.