Fuel Tank: Installation

1. Install 8 new fuel tank cushions to the fuel tank.
   Fig 1: Identifying Fuel Tank Cushion

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1. Install the clamp to the fuel tank.
   Fig 2: Identifying Fuel Tank Clamp

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2. Install the 2 fuel tube clamps of the fuel tank main tube to the fuel tank.
   Fig 3: Identifying Fuel Tank Main Tube Clamps

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1. Install the fuel tank main tube to the clamp.
   Fig 4: Identifying Fuel Tank Main Tube Sub-Assembly

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1. Install the fuel tank wire.
   Fig 5: Identifying Fuel Tank Wire

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1. Connect the fuel tank vent hose to the fuel tank.
   Fig 6: Connecting Fuel Tank Vent Hose To Fuel Tank

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2. Install the 2 nuts to the fuel vapor containment valve.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

   Fig 7: Identifying Fuel Vapor Containment Valve Nuts

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3. Connect the connector and clamp.
   Fig 8: Identifying Connector And Clamp

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1. Install a new gasket on the fuel pump assembly.
2. Install the fuel pump assembly.
   Fig 9: Identifying Fuel Pump Assembly

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3. Install the fuel tank vent tube set plate by aligning it with the cutout on the fuel pump assembly.
4. Install the fuel tank vent tube set plate and fuel pump connector plate with the 8 bolts.

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

   Fig 10: Identifying Fuel Tank Vent Tube Set Plate And Fuel Pump Connector Plate Bolts

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5. Connect the fuel tank main tube with the tube joint clip and clamp.
   NOTE:

   • Check that there is no scratches or foreign objects on the connecting part.
   • Check that the fuel tube joint is inserted securely.
   • Check that the tube joint clip is on the collar of the fuel tube joint.
   • After installing the tube joint clip, check that the fuel tube joint is pulled off.
   Fig 11: Connecting Fuel Tank Main Tube With Tube Joint Clip And Clamp

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6. Connect the fuel tank wire connector.
7. Connect the vapor pressure sensor connector and clamp.
   Fig 12: Identifying Fuel Tank Wire Connector, Vapor Pressure Sensor Connector And Clamp

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1. Set the fuel tank on a transmission jack.
2. Operate the transmission jack, and install the fuel tank to the vehicle.
3. Operate the transmission jack, and connect the fuel tank inlet pipe with the tube connector and clamp.
   Fig 13: Identifying Fuel Tube Connector And Fuel Filler Pipe Clamp

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

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

   Fig 14: Identifying Fuel Tank Bands

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1. Connect the breather lower tube.
   1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
      NOTE:

      • Check for damage or foreign objects on the connected part of the fuel pipe.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
2. Install the checker to the pipe.
   Fig 15: Connecting Breather Lower Tube

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1. Connect the fuel tank main tube sub-assembly.
   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 objects on the connected part.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 16: Connecting Fuel Tank Main Tube Sub-Assembly

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1. Align the quick connector with the pipe, then push in the quick connector until the retainer makes a "click" sound to connect the charcoal canister fuel hose to the charcoal canister assembly.
   Fig 17: Connecting Charcoal Canister Fuel Hose

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   NOTE:

   • Check for scratches or foreign objects around the connected part of the quick connector and pipe before this work.
   • After connecting the charcoal canister fuel hose, check that the charcoal canister fuel hose is securely connected by pulling on the quick connector.

1. Connect the clamp to the charcoal canister protector.
2. Install the charcoal canister protector with the 3 bolts.

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

   Fig 18: Identifying Charcoal Canister Protector

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1. Connect the fuel tank wire connectors, and install them to the bracket.
   Fig 19: Identifying Fuel Tank Wire

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1. Install the parking brake cable assembly No. 3 with the nut.

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

   Fig 20: Identifying Parking Brake Cable Assembly No. 3

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1. Install the fuel tank protector sub-assembly No. 1 with the screw and the 4 grommets.
   Fig 21: Identifying Fuel Tank Protector Sub-Assembly No. 1

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1. Install the front floor heat insulator No. 3 with the 5 nuts.

   Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 

   Fig 22: Identifying Front Floor Heat Insulator No. 3 Nuts

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(See INSTALLATION )

Some systems need initialization after reconnecting the cable to the negative battery terminal. (See INITIALIZATION )