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 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.
   

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 cushions.

Attach the 4 harness clips and connect the fuel pump connector to the fuel tank.

NOTICE:

Be careful not to cut the wirings.

Install the 2 fuel tank bands with the 2 pins and 2 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 2 hoses to the 2 tubes.

Move the clamps to the connection points.

NOTICE:

Check that there is no damage or foreign matter on the connected part of the pipe.

Install the fuel tank protector with the 4 nuts.

Torque:

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

Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

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

HINT:

When checking for fuel leaks, make sure that there is pressure in the fuel line.