GSIC - Global Service Information Center

# FUEL TANK > INSTALLATION

## for Preparation Click here

1. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

1. Put the retainer on the fuel tank. While holding the pump tube, tighten the retainer one complete turn by band.

1. 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.

1. 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.

2. INSTALL NO. 1 FUEL TANK CUSHION

1. Install 2 new fuel tank cushions.

1. Install the clip to the cushion on the front side.

   HINT:
     Install only 1 clip so that the cushion can be folded back and the wire harness can be installed when the fuel tank assembly is installed to the vehicle.

1. Install the heat insulator with the 4 new clips and nut.

3. INSTALL FUEL TANK ASSEMBLY

1. Set a mission jack to the fuel tank.

1. Lift up the mission jack.

1. Fold back the 2 cushion rubbers.

1. Connect the 6 harness clips and fuel pump connector to the fuel tank.

   NOTICE:
     Be careful not to cut the wirings.

1. Install the cushion rubber on the front side with the remaining clip.

1. Install the 2 fuel tank bands with the 2 pipes and 2 clips.

1. Connect the 2 fuel tank bands with the 2 bolts.

   Torque:
     61 N*m{ 622 kgf*cm , 45 ft.*lbf }

4. INSTALL FUEL TANK FILLER PIPE

1. Install the filler pipe with the bolt.

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

5. CONNECT FUEL TANK TO FILLER PIPE HOSE

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

6. CONNECT FUEL TANK BREATHER HOSE

1. Connect the fuel tank breather hose to the fuel tank filler pipe.

7. CONNECT FUEL MAIN TUBE

NOTICE:

  Before installing the tube connectors to the pipes, check the connectors for damage and foreign matter.

1. Connect the return tube connector to the pipe. Then connect the main tube connector to the pipe. Push the 2 parts together firmly until a "click" sound heard.

   NOTICE:
     Check that the connectors and pipes are securely connected by trying to pull them apart.

1. Connect the EVAP hose.

8. INSTALL NO. 3 FUEL TUBE CLAMP

1. Install the tube clamp to the fuel tube.

9. INSTALL FUEL TANK CAP

10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

11. 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.

12. CHECK FOR FUEL LEAKS

1. Connect the intelligent tester to the DLC3.

   1. Turn the ignition switch ON.

      NOTICE:
        Do not start the engine.

   2. Push the intelligent tester main switch ON.

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

1. Check for fuel leaks.

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