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 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 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 the range labeled B.
   
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 approximately half of each cushion so that the wire harness can be installed in the step below.

Attach the wire harness to the 4 clamps and connect the fuel pump and sender gauge connector.

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 in.*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 main tube and fuel tank return tube.

Install the fuel tank protector with the 4 nuts.

Torque:

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

Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and push the intelligent tester main switch on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.