Fuel Tank: Installation

1. Install 4 new No. 1 fuel tank cushions onto the fuel tank.
   Fig 1: Identifying 4 Fuel Tank Cushions No. 1

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1. Install the fuel tank vent hose onto the fuel tube clamp.
   Fig 2: Locating Fuel Tank Clamp

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1. Install the fuel tank main tube onto the fuel tank.
   Fig 3: Locating Fuel Tank Main Tube

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1. Set the fuel tank on a transmission jack (A).
2. Operate the transmission jack, then install the fuel tank into the vehicle (B).
3. Install the 2 fuel tank bands No. 1 with the 4 bolts (C).

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

   Fig 4: Locating Fuel Tank Bands No. 1 Bolts

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4. Connect the fuel tank to filler pipe hose to the fuel tank (D).
   NOTE: Make sure that the hose clamp is facing in the correct direction when installing.
   Fig 5: Connecting Fuel Tank To Filler Pipe Hose To Fuel Tank

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5. Engage the claw, then install the fuel tank filler pipe cover onto the fuel tank filler pipe (E).
   Fig 6: Identifying Fuel Tank Filler Pipe Cover Claw

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6. Connect the fuel tank vent hose (F).
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank vent hose to the pipe.
   2. Slide the retainer of the fuel tube connector to lock the claws as shown in the illustration.
      NOTE:

      • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tube connector.
        Fig 7: Connecting Fuel Tank Vent Hose

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7. Connect the fuel tank breather tube (G).
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound to connect the fuel tank breather tube to the pipe.
      NOTE:

      • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tank breather tube, check that the fuel pump tube is securely connected by pulling the fuel tube connector and pipe.
        Fig 8: Connecting Fuel Tank Breather Tube

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   2. Install the checker onto the pipe.
8. Connect the fuel tank main tube (H).
   1. Align the fuel tube connector with the pipe, then push the fuel tube connector in until it comes into contact with the seat to connect the fuel tank main tube to the pipe, then push the retainer up until the claws lock.
      NOTE:

      • Check that there are no scratches or foreign objects around the connected part of the fuel tube connector and pipe before performing this work.
      • After connecting the fuel tank main tube, check that the fuel tank main tube is securely connected by pulling the fuel tube connector and pipe.
        Fig 9: Connecting Fuel Tank Main Tube

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1. Align the turn prevention positions, then connect the No. 3 parking brake cable with the 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Fig 10: Connecting Parking Brake Cable No. 3

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1. Align the turn prevention positions, then connect the No. 2 parking brake cable with the 2 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Fig 11: Connecting Parking Brake Cable No.2

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1. Check the free length (A).
   1. Using vernier calipers, measure the free length of the compression spring.

      Minimum: Exhaust manifold side: 41.5 mm (1.6339 in.) 

      Exhaust pipe tail side: 38.5 mm (1.5158 in.) 

      Fig 12: Measuring Free Length Of Compression Spring

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      If the free length is less than the minimum, replace the compression spring.

2. Using a wooden block and plastic-faced hammer, tap a new gasket into the exhaust manifold (B).
   NOTE:

   • Make sure that the gasket is installed in the correct direction.
   • Do not reuse a removed gasket.
   • Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust manifold.
     Fig 13: Locating Exhaust Manifold Gasket

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3. Using a wooden block and plastic-faced hammer, tap a new gasket into the exhaust tail (C).
   NOTE:

   • Make sure that the gasket is installed in the correct direction.
   • Do not reuse a removed gasket.
   • Never push the gasket into the exhaust manifold by installing the exhaust pipe front onto the exhaust tail.
4. Install the exhaust pipe front onto the 2 exhaust pipe supports No. 4 (D).
5. Tighten the 4 compression springs and 4 bolts (E).

   Torque: 43 N*m (440 kgf*cm, 32 ft.*lbf) 

   Fig 14: Locating Gasket On Exhaust Tail

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   Fig 15: Locating Exhaust Pipe Supports No. 4 And Bolts

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6. Install the floor panel brace front with the 2 nuts (F).

   Torque: 30 N*m (302 kgf*cm, 22 ft.*lbf) 

   Fig 16: Locating Floor Panel Brace Nuts

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7. Pull the connector back inside the vehicle, then install the grommet (G).
8. Connect the heated oxygen sensor connector (H).
   Fig 17: Locating Heated Oxygen Sensor Connector And Grommet

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9. Install the floor carpet front with the clip (I).

Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

Fig 18: Installing Floor Carpet Front With Clip

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1. Install the No. 1 fuel tank protector with the 4 bolts.