Fuel Tank: Installation

1. Install the No 1 fuel tank protector to the fuel tank assembly

Fig 1: Identifying Fuel Tank Protector

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1. Install 11 new fuel tank cushions as shown in the illustration.

Fig 2: Identifying Fuel Tank Cushions

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1. Install the fuel tank vent hose with the clip.

Fig 3: Locating Fuel Tank Vent Hose Clip

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1. Install the fuel tank to filler pipe hose to the fuel tank assembly with the clamp

Fig 4: Locating Fuel Tank To Filler Pipe Hose Clamp Bolt

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1. Install the 2 tank bracket retainer sub-assemblies.
   Fig 5: Locating Tank Bracket Retainer Sub-Assemblies

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2. Install the edge protector with the 2 clamps.
   Fig 6: Identifying Edge Protector Clamps

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3. Install a fuel tank main tube and fuel tank return vent tube with the clamp.
Fig 7: Identifying Fuel Tank Main Tube And Fuel Tank Return Vent Tube
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1. Install a new gasket to the No 1 fuel tank breather tube sub-assembly.
2. 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) 

   Fig 8: Locating Fuel Tank Breather Tube Bolts

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1. Set the fuel tank assembly onto an engine lifter
2. Raise the engine lifter so that the No 1 fuel tank breather tube sub-assembly can be connected Connect the hose.
   NOTE: Slowly raise the lifter so as to not drop the fuel tank assembly.
   Fig 9: Locating Fuel Tank Breather Tube

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3. Install the fuel tank assembly with the fuel tank bands and 4 bolts

   Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

   Fig 10: Locating Fuel Tank Bands Bolts

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1. Connect the fuel tank vent hose with the clamp.

1. Connect the fuel tank to filler pipe hose with the clamp
   Fig 11: Locating Fuel Tank To Filler Pipe Hose Clamp Bolt

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1. Connect the fuel tank main tube (RH side).
   1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws
      NOTE:

      • Check for damage or foreign matter on the connected part.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 12: Locating Fuel Tank Main Tube (RH Side)
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2. 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.
      NOTE:

      • Check for damage or foreign matter on the connected part.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 13: Locating Fuel Tank Return Vent Tube
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3. Connect the fuel tank main tube (LH side)
   1. Push in the fuel tube connector to the pipe and push up the retainer to engage the claws.
      NOTE:

      • Check for damage or foreign matter on the connected part.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 14: Locating Fuel Tank Main Tube (LH Side)
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1. Install the bolt, loosen the grommet then install No 3 fuel tank protector

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

2. Install the bolt, loosen the grommet then install No 4 fuel tank protector.

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

   Fig 15: Locating Fuel Tank Protector Bolts

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3. Connect the 4 clamps
4. Connect the 2 parking brake cable assemblies with the 4 bolts.

   Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) for bolt A 

   19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt B 

   Fig 16: Locating Parking Brake Cable Assemblies Bolts

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HINT

See INSTALLATION

HINT.

See INSTALLATION

HINT:

Use the same procedure as for the No 2 differential support protector

1. Install the fuel sender gauge to the fuel tank with the 5 bolts

   Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) 

   NOTE: Be careful not to bend the arm of the fuel sender gauge.
   Fig 17: Locating Fuel Sender Gauge Bolts

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2. Connect the fuel sender gauge connector

Fig 18: Locating Fuel Sender Gauge Connector

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

Fig 19: Identifying Rear Floor Service Hole Cover

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