Fuel Tank Installation

Install the No. 2 fuel tank protector to the fuel tank assembly.

Install 11 new fuel tank cushions as shown in the illustration.

Install the fuel tank vent hose with the clip.

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

Tighten the hose clamp bolt.

Install the edge protector with the 2 clamps.

Install a fuel tank main tube and fuel tank return vent tube with the clamp.

Install a new gasket to the No. 1 fuel tank breather tube sub-assembly.

Install the No. 1 fuel tank breather tube sub-assembly with the 4 bolts.

Torque:

1.5 N*m{15 kgf*cm, 13 in.*lbf}

Set the fuel tank assembly onto the transmission jack.

Raise the transmission jack so that the fuel tank breather hose can be connected. Connect the hose.

NOTICE:

Slowly raise the jack not to drop the fuel tank assembly.

Install the fuel tank assembly with the fuel tank band and 4 bolts.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Connect the fuel tank vent hose with the clamp.

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

Connect the fuel tank main tube.

1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
   

   NOTICE:

   1. Check for damage or foreign objects on the connected part.
      
   2. After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      

Connect the fuel tank return vent tube.

1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
   

   NOTICE:

   1. Check for damage or foreign objects on the connected part.
      
   2. After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      

Connect the 4 clamps.

Connect the 2 parking brake cables with the 4 bolts.

Torque:

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

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

Install the rear suspension member brace LH with the 2 bolts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Install the No. 2 differential support protector to the rear suspension member brace with the 2 nuts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Install the fuel sender gauge to the fuel tank with the 5 bolts.

Torque:

1.5 N*m{15 kgf*cm, 13 in.*lbf}

Connect the fuel sender gauge connector.

Install a new gasket onto the fuel tank.

Connect the fuel hose with the clip.

Set the fuel suction tube to the fuel tank.

NOTICE:

1. Make sure that the fuel sender gauge arm does not bend.
   
2. Do not damage the No. 2 fuel hose.
   

Align the protrusion of the fuel suction tube and the cutout of the fuel tank vent tube set plate.

While holding the fuel suction tube by hand, install the fuel tank vent tube to the fuel tank with the 8 bolts.

Torque:

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

Connect the fuel tube.

1. Push the fuel tube joint in the plug of the fuel suction plate, then install 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.
      

Connect the fuel suction tube connector.

Connect the intelligent tester to the DLC3.

1. Turn the engine switch on (IG).
   

   NOTICE:

   Do not start the engine.

2. Push the intelligent tester main switch ON.
   

3. Select the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump /Speed.
   

Check the fuel pump operation.

1. Check for pressure in the fuel inlet tube from the fuel line. Check that sound of fuel flowing in the fuel tank can be heard.
   If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.
   

Check for fuel leaks.

1. Check that there are no fuel leaks anywhere on the system after performing maintenance.
   If there is a fuel leak, repair or replace parts as necessary.
   

Install the service hole cover with new butyl tape.

Install the No. 2 rear floor service hole cover with new butyl tape.

Attach the 2 rear hooks of the seat cushion to the seatback.

Attach the 2 front hooks of the seat cushion to the vehicle body.

Confirm that the seat cushion is firmly installed.

NOTICE:

When installing the seat cushion, make sure the seat belt buckle is not under the seat cushion.

Perform initialization (Click here).

HINT:

Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.