FUEL TANK > INSTALLATION

for Preparation Click here



1. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


A096589

  1. Install the tank protector with the 2 nuts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



2. INSTALL FUEL TANK CUSHION


A109999

  1. Install the tank cushions and tank brackets.



3. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


A110155

  1. Install the fuel tank main tube to the 2 clamps.



4. INSTALL FUEL TANK SUB-ASSEMBLY

  1. Set a mission jack to the fuel tank and lift it up.

  1. Install the 2 fuel tank bands with the 4 bolts.

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

  1. Install the 2 nuts.

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



5. CONNECT EMISSION HOSE


A108370

  1. Connect the 2 fuel emission hoses.

  1. Install the bracket.



6. CONNECT FUEL TANK TO FILLER PIPE HOSE


A094985

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



7. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


A111017

  1. Connect the fuel tank main tube connector.

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

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

  1. Install the fuel hose connector cover to the pipe.



8. CONNECT PARKING BRAKE CABLE ASSEMBLY


A105893E01

  1. Connect the 4 clamps.

  1. 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{ 193 kgf*cm , 14 ft.*lbf } for bolt B



9. INSTALL REAR FLOOR SIDE MEMBER COVER LH


A109735

  1. Install the side member cover with the 2 bolts.



10. INSTALL REAR FLOOR SIDE MEMBER COVER RH


A109736

  1. Install the side member cover with the 2 bolts.



11. INSTALL NO. 1 DIFFERENTIAL SUPPORT PROTECTOR


A105891

  1. Install the differential support protector with the 2 nuts.



12. INSTALL NO. 2 DIFFERENTIAL SUPPORT PROTECTOR

  1. Install the differential support protector with the 2 nuts.



13. INSTALL NO. 2 FUEL TANK PROTECTOR


A105888

  1. Install the tank protector with the 4 nuts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 48 in.*lbf }



14. ADJUST PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    C109590E01

  1. Remove the SST from the transmission.

    SST
    09325-40010  

  1. Insert the yoke of the intermediate shaft into the transmission.

    HINT:
    Be careful not to damage the oil seal.



    F048233

  1. Install the 2 center support bearing washers and center support bearing, and temporarily tighten the 2 bolts.



    C104521E01

  1. Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts.

    Torque:
    74 N*m{ 750 kgf*cm , 54 ft.*lbf }



    C109187E01

  1. Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 in.) respectively as shown in illustration.



    C109375E01

  1. Check that the center line of the bracket is at right angles to the shaft axial direction.



    F048233

  1. Tighten the 2 bolts.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }



15. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR


A109865

  1. Install the heat insulator with the 4 nuts.



16. INSTALL FRONT FLOOR COVER CENTER RH


A109461E01

  1. Install the floor cover center with the 3 nuts.



17. INSTALL EXHAUST PIPE ASSEMBLY

  1. Install the exhaust pipe (Click here).



18. INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY


    A111009

  1. Install the fuel sender gauge.

    1. Set the fuel sender gauge to the fuel vent tube. Then slide the sender gauge downward to install it.

    2. Connect the fuel sender gauge connector.



    A111011E01

  1. Set the fuel return vent tube to the fuel tank.

  1. Apply a light coat of gasoline to a new gasket, and set it to the fuel tank.

  1. Connect the fuel tube connector, and set the fuel suction with pump and gauge.

    NOTICE:
    1. Be careful not to bend the arm of the fuel sender gauge.
    1. When connecting the fuel tube connector, do not forcibly pull the tube.

  1. Align the protrusion of the fuel suction tube and the cutout of the fuel tank.



    A101963E01

  1. While holding the fuel suction tube by hand, align the start marks of a new fuel pump gauge retainer and the fuel tank. Install the fuel pump retainer to the fuel tank.



    A110152E01

  1. Using a 6 mm socket, set SST to the fuel pump gauge retainer.

    SST
    09808-14020  

    NOTICE:
    Do not use any other tools such as a screwdriver.

    HINT:
    Fit the tips of SST on the ribs of the retainer.



    A110163E01

  1. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that that the start mark on the retainer is within the indicated range in the illustration.



19. INSTALL REAR FLOOR SERVICE HOLE COVER


A110526

  1. Connect the fuel sender gauge connector.

  1. Install the service hole cover with new butyl tape.



20. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

  1. Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.

  1. Connect the fuel tube connector, and set the fuel suction with pump and gauge.

    NOTICE:
    1. Be careful not to bend the arm of the fuel sender gauge.
    1. When connecting the fuel tube connector, do not forcibly pull the tube.



    A095022E01

  1. Align the protrusion of the fuel suction tube and the cutout of the fuel tank.



    A100681E01

  1. While holding the fuel suction tube by hand, align the starting marks of a new fuel pump gauge retainer and the fuel tank. Install the fuel pump retainer to the fuel tank.



    A094978E01

  1. Using a 6 mm socket, set SST to the fuel pump gauge retainer.

    SST
    09808-14020  

    NOTICE:
    Do not use any other tools such as a screwdriver.

    HINT:
    Fit the tips of SST on the ribs of the retainer.



    A101968E01

  1. Hold SST with one hand and use SST to tighten the fuel pump gauge retainer 2 turns so that the start mark on the retainer is within the indicated range in the illustration.



    A101969E02

  1. Connect the fuel tank main tube.

    1. Push the fuel tube joint into the plug of the fuel suction plate, then install the 2 tube joint clips.

  1. Connect the fuel suction tube connector.

    NOTICE:
    1. Check that there are no scratches or foreign matter around the connected part of the fuel tube joint and plug before performing this work.
    1. Check that the fuel tube joint is securely inserted.
    1. Check that the tube joint clip is on the collar of the fuel tube joint.
    1. After installing the tube joint clip, check that the fuel tube cannot be pulled out.



21. INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER


A110130

  1. Connect the fuel pump connector.

  1. Install the service hole cover with new butyl tape.



22. INSTALL ROOM NO. 3 PARTITION PAD


A100590E01

  1. Install the partition pad with the clip.



23. INSTALL REAR SEAT CUSHION ASSEMBLY


B105974E01

  1. Attach the seat cushion's 2 rear hooks to the seatback.

  1. Attach the seat cushion's 2 front hooks to the vehicle body.

  1. 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.



24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


25. CHECK FOR FUEL LEAKS

  1. Start the engine, and check that there are no fuel leaks after performing maintenance anywhere on the system.



26. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    NOTICE:
    Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.