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 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 cushions.

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 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 TANK MAIN TUBE AND FUEL TANK RETURN TUBE

1. Connect the 2 hoses to the 2 tubes.

1. Move the clamps to the connection points.

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

8. INSTALL NO. 1 FUEL TANK PROTECTOR

1. Install the fuel tank protector with the 4 nuts.

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

9. TIGHTEN FUEL TANK CAP

10. BLEED AIR FROM FUEL SYSTEM

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

11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

12. 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.

13. CHECK FOR FUEL LEAKS