Fuel Tank Installation

Install the No. 1 fuel tank heat insulator with the 4 clips.

Install the fuel tube clamp to the No. 1 fuel tank heat insulator.

Install the fuel tank to filler pipe hose to the fuel tank sub-assembly as shown in the illustration and tighten the hose clamp.

HINT:

1. Align the fuel tank side mark with the hose side mark when installing the hose.
   


2. Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
   

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 assembly into the fuel tank.

Text in Illustration

*1	Protrusion
*2	Groove
	Front

NOTICE:

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

HINT:

Align the protrusion of the fuel suction with pump and gauge tube assembly with the groove of the fuel tank.

Put the fuel pump gauge retainer on the fuel tank. While holding the fuel suction with pump and gauge tube assembly, tighten the fuel pump gauge retainer 1 complete turn by hand.

Set SST on the fuel pump gauge retainer.

SST

09808-14030

HINT:

1. Hold the fuel suction with pump and gauge tube assembly upright by hand to make sure that the fuel suction tube gasket is not moved out of position.
   
2. Engage the claws of SST securely with the fuel pump gauge retainer holes to secure SST.
   
3. Install SST while pressing the claws of SST against the fuel pump gauge retainer (toward the center of SST).
   

Using SST, tighten the fuel pump gauge retainer until the mark on the fuel pump gauge retainer is within range A on the fuel tank as shown in the illustration.

SST

09808-14030

HINT:

Fit the tips of SST onto the ribs of the fuel pump gauge retainer.

Install the 3 fuel tube joints with the 3 tube joint clips.

NOTICE:

1. Check that there are no scratches or foreign objects on the connecting parts.
   
2. Check that the fuel tube joints are 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 cannot be pulled off.
   

for G.C.C. Countries:

1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.
   

2. Attach the clamp and install the fuel tank return tube sub-assembly.
   

3. Attach the clamp and install the fuel tank main tube sub-assembly.
   

except G.C.C. Countries:

1. Attach the 2 clamps and install the No. 2 fuel tank main tube sub-assembly.
   

2. Attach the clamp and install the fuel tank return tube sub-assembly.
   

3. Attach the clamp and install the fuel tank main tube sub-assembly.
   

for G.C.C. Countries:
Install the fuel hose to the fuel suction tube sub-assembly, and slide the clip to secure the hose.

Install the 2 fuel tube joints 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 joints are 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 cannot be pulled off.
   

Attach the clamp and install the fuel tank return tube sub-assembly.

Attach the clamp and install the fuel tank main tube sub-assembly.

Set the fuel tank sub-assembly on an engine lifter and raise the fuel tank sub-assembly.

NOTICE:

Do not allow the fuel tank sub-assembly to contact the vehicle, especially the differential.

Raise the engine lifter.

Install the 2 fuel tank band sub-assemblies with the 2 pins and 2 clips.

Connect the 2 fuel tank band sub-assemblies with the 2 bolts.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Connect the fuel tank to filler pipe hose to the fuel tank to filler pipe sub-assembly as shown in the illustration and tighten the hose clamp.

HINT:

1. Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.
   


2. Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
   

Connect the fuel tank to filler pipe hose to the fuel tank to filler pipe sub-assembly as shown in the illustration and tighten the hose clamp.

HINT:

1. Install the hose so that the distance between the fuel tank inlet pipe side mark and fuel tank to filler pipe hose side mark is 0 to 0.3 mm (0 to 0.0118 in.) as shown in the illustration.
   


2. Tighten the hose clamp until the end of the hose clamp contacts the stopper as shown in the illustration.
   

Connect the fuel tank breather tube to the fuel tank to filler pipe sub-assembly and push the retainer.

Text in Illustration

*1	Retainer
	Push

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

Connect the fuel tank breather tube to the fuel tank to filler pipe sub-assembly and push the retainer.

Text in Illustration

*1	Retainer
	Push

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

except G.C.C. Countries:

1. Connect the No. 2 fuel tank breather tube and push the retainer.
   

   NOTICE:

   1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      
   2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      

   Text in Illustration

   *1	Retainer
   *2	Connector
   *3	O-Ring
   *4	Pipe
   *5	Nylon Tube
   	Push

   HINT:

   Push the parts together firmly until a "click" sound is heard.

2. Attach the fuel tube clamp.
   

Connect the No. 2 fuel tank main tube sub-assembly and push the retainer.

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

for G.C.C. Countries:

1. Connect the fuel hose to the pipe, and slide the clip to secure the hose.
   

2. Attach the fuel tube clamp.
   

except G.C.C. Countries:

1. Connect the No. 1 fuel emission tube sub-assembly and push the retainer.
   

   NOTICE:

   1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      
   2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      

   Text in Illustration

   *1	Retainer
   *2	Connector
   *3	O-Ring
   *4	Pipe
   *5	Nylon Tube
   	Push

   HINT:

   Push the parts together firmly until a "click" sound is heard.

2. Attach the fuel tube clamp.
   

for G.C.C. Countries:

1. Connect the No. 1 fuel emission tube sub-assembly and push the retainer.
   

   NOTICE:

   1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
      
   2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
      

   Text in Illustration

   *1	Retainer
   *2	Pipe
   *3	Nylon Tube
   *4	Connector
   *5	O-Ring
   	Push

   HINT:

   Push the parts together firmly until a "click" sound is heard.

2. Attach the fuel tube clamp.
   

Connect the fuel tank return tube and push the retainer.

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

Connect the fuel tank return tube and push the retainer.

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

Text in Illustration

*1	Retainer
*2	Pipe
*3	Nylon Tube
*4	Connector
*5	O-Ring
	Push

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

for G.C.C. Countries:

1. Connect the No. 2 fuel tank breather hose to the pipe, and slide the clip to secure the hose.
   

2. Attach the fuel pipe clamp.
   

Connect the No. 2 fuel tank breather tube and push the retainer.

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

Text in Illustration

*1	Retainer
*2	Pipe
*3	Nylon Tube
*4	Connector
*5	O-Ring
	Push

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

Connect the fuel tank main tube sub-assembly and push the retainer.

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

Connect the fuel tank main tube sub-assembly and push the retainer.

NOTICE:

1. Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
   
2. After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.
   

Text in Illustration

*1	Retainer
*2	Pipe
*3	Nylon Tube
*4	Connector
*5	O-Ring
	Push

HINT:

Push the parts together firmly until a "click" sound is heard.

Attach the fuel tube clamp.

Install the No. 1 fuel tank protector sub-assembly with the 5 bolts.

Torque:

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

Connect the fuel pump and fuel sender gauge connector.

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

w/ Rear Air Conditioning System:
Install the air duct and 2 screws.

Make sure that there are no fuel leaks after performing maintenance on the fuel system.

1. Connect the GTS to the DLC3.
   

2. Turn the engine switch on (IG) and turn the GTS on.
   

   NOTICE:

   Do not start the engine.

3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
   

4. Check that there are no leaks from the fuel system.
   If there are fuel leaks, repair or replace parts as necessary.
   

5. Turn the engine switch off.
   

6. Disconnect the GTS from the DLC3.