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

Tighten the hose clamp bolt.

Install the 3 clamps to the fuel tank.

Install the fuel tank return tube sub-assembly with the 3 clamps.

Install the clamp to the fuel tank.

Install the fuel tank main tube sub-assembly with the clamp.

Install the fuel tank vent hose with the clip.

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 to prevent the fuel tank assembly from dropping.

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

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}

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

Connect the fuel tube clamp.

Connect the 2 fuel tubes to the fuel sedimenter assembly.

Connect the fuel tube to the fuel filter.

Connect the 3 fuel tubes to the fuel route switching valve.

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 parts that are to be connected.
      
   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 parts that are to be connected.
      
   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:

bolt A:

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

bolt B:

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

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

Torque:

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

Stabilize the propeller shaft and differential.

1. Turn the propeller shaft several times by hand to stabilize the center support bearing.
   

Check both the No. 2 and No. 3 joint angles.

1. Using SST, measure the installation angle of the intermediate shaft and propeller shaft.
   

   SST

   09370-50010
   

   HINT:

   The SST should be set directly on the bottom of the shaft.





2. Using SST, measure the installation angle of the differential.
   
   

   
   
   
   

   SST

   09370-50010
   

   HINT:

   Measure the installation angle by placing the SST in the positions shown in the illustration.

3. Calculate the No. 2 joint angle.
   

   No. 2 joint angle:

   A - B = -0°49' to -1°49'
   

   A:

   Intermediate shaft installation angle
   

   B:

   Propeller shaft installation angle
   

4. Calculate the No. 3 joint angle.
   

   No. 3 joint angle:

   B - C = 0°70' to 2°10'
   

   B:

   Propeller shaft installation angle
   

   C:

   Differential installation angle
   

   HINT:

   If the measured angle is not within the specified range, adjust it with the center support bearing washers.

Adjust the No. 2 joint angle.

1. Select the center support bearing washers for adjustment.
   

   Adjustment washer

   thickness mm (in.)

   2 (0.0787)

   4.5 (0.1772)

   6.5 (0.2559)

   9.0 (0.3543)

   11.0 (0.4331)

   NOTICE:

   The 2 washers should be the same thickness.

Install the front No. 1 floor heat insulator with the 4 nuts.

Torque:

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

Install the outside air guide plate RH with the 4 nuts.

Torque:

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

Before installing the air fuel ratio sensor, twist the sensor wire counterclockwise 4 turns.

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST

09224-00010

Torque:

44 N*m{449 kgf*cm, 33 ft.*lbf}

Install the front center floor brace with the 4 bolts.

Torque:

7.4 N*m{75 kgf*cm, 65 in.*lbf}

Install the suspension member brace lower LH with the 4 bolts.

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

Install the suspension member brace lower RH with the 4 bolts.

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

Install the rear No. 1 floor panel brace with the 4 bolts.

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

Install the No. 1 floor under cover and No. 2 floor under cover.

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.

Pull firmly on the parking brake lever.

Release the parking brake lock, and return the parking brake lever to its off position.

Slowly pull the parking brake lever all the way up, and count the number of clicks.

Parking brake lever travel:

4 to 6 notches at 200 N (20 kgf, 45 lbf)

Depress the parking brake lever. Hold the No. 1 wire adjusting nut using a wrench and loosen the lock nut.

Release the parking brake lever.

Turn the No. 1 wire adjusting nut until the parking brake lever travel meets the above specification.

Hold the No. 1 wire adjusting nut using a wrench or equivalent tool and tighten the lock nut.

Torque:

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

Count the number of clicks after depressing and releasing the parking brake lever 3 or 4 times.

Check whether the parking brake drags or not.

When operating the parking brake lever, check that the parking brake indicator light comes on.

PERFORM ACTIVE TEST

1. Connect the intelligent tester to the DLC3.
   

2. Turn the engine switch ON (IG).
   

3. Turn the intelligent tester ON.
   

4. Enter the following menus: Powertrain / ENGINE / Active Test.
   

5. Perform the Active Test.
   
   

   Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
   Test the Fuel Leak	Pressurize common rail internal fuel pressure, and check for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when "Start" is selected Above conditions to be maintained while "Start" is selected

Install the service hole cover with new butyl tape.

Install the rear No. 2 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 procedure (Click here).

HINT:

Some vehicle systems require initialization after reconnecting the negative battery terminal.