FUEL TANK > INSTALLATION

for Preparation Click here



1. INSTALL NO. 1 EVAPORATION VENT TUBE CLAMP


    A202860

  1. Engage the 2 claws and install the No. 1 evaporation vent tube clamp.



2. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    A202950E01

  1. Insert the fuel tank vent tube from the sender gauge side, in the direction indicated by the arrows on the fuel tank, run the tube along the bottom edge of the fuel tank, and then pull it out on the fuel pump side.
    Text in Illustration 
    *1
    		Arrows
    *2
    		Recession

    NOTICE:
    Do not run the fuel tank vent tube on the other side of the recession shown in the illustration.



3. INSTALL FUEL TANK SUCTION TUBE GASKET


    A199536

  1. Install a new gasket to the fuel tank.



4. INSTALL FUEL SUCTION TUBE ASSEMBLY


    A202897

  1. Line up the pipe and connector and push them together until a "click" sound is heard.

    NOTICE:
    1. Check that there are no scratches or foreign objects on the connecting part.
    2. After connecting the pipe and connector, check that the pipe and connector are securely connected by pulling on them.

  1. Install the fuel suction tube assembly to the fuel tank.



5. INSTALL FUEL PUMP GAUGE RETAINER


    A202893E01

  1. Align the protrusion of the fuel suction tube assembly with the cutouts of the fuel tank.
    Text in Illustration 
    *1
    		Cutout

    NOTICE:
    Ensure that the fuel suction tube gasket is in the correct position.

  1. While holding the fuel suction tube assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

    NOTICE:
    Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.



    A202891E01

  1. Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer.

    SST
    09808-14020   (09808-01410, 09808-01420, 09808-01430)

    NOTICE:
    Do not use any tools other than SST.

    HINT:
    1. Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.
    2. Align the ribs of the fuel pump gauge retainer with the tips of SST.



    A202894E01

  1. Using SST, align the marks on the fuel tank and fuel pump gauge retainer.

    SST
    09808-14020   (09808-01410, 09808-01420, 09808-01430)



6. INSTALL FUEL TANK SUCTION TUBE GASKET


    A199533

  1. Install a new gasket to the fuel tank.



7. INSTALL FUEL TANK VENT TUBE ASSEMBLY


    A203004

  1. Engage the 2 claws and connect the fuel tank vent tube sub-assembly to the fuel tank vent tube assembly.



    A203005E01

  1. Rotate the fuel tank vent tube in the direction shown by the arrows, insert the sender gauge in the direction of the fuel tank gauge shown by the arrows, and then install the fuel tank vent tube assembly into the fuel tank.
    Text in Illustration 
    *1
    		Arrows

    NOTICE:
    Do not bend the sender gauge arm.



8. INSTALL FUEL PUMP GAUGE RETAINER


    A202889E01

  1. Align the protrusion of the fuel tank vent tube assembly with the cutouts of the fuel tank.
    Text in Illustration 
    *1
    		Cutout

    NOTICE:
    Ensure that the fuel suction tube gasket is in the correct position.

  1. While holding the fuel tank vent tube assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

    NOTICE:
    Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.



    A202887E01

  1. Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer.

    SST
    09808-14020   (09808-01410, 09808-01420, 09808-01430)

    NOTICE:
    Do not use any tools other than SST.

    HINT:
    1. Hold the fuel tank vent tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.
    2. Align the ribs of the fuel pump gauge retainer with the tips of SST.



    A202890E01

  1. Using SST, align the marks on the fuel tank and fuel pump gauge retainer.

    SST
    09808-14020   (09808-01410, 09808-01420, 09808-01430)



9. INSTALL NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    A202886E01

  1. Connect the No. 1 fuel evaporation tube to the fuel suction tube and fuel tank vent tube assemblies and lock them by pushing in the retainers.

    NOTICE:
    1. Check that there are no scratches or foreign objects on the connecting part.
    2. Check that the No. 1 fuel evaporation tube is inserted securely.
    3. After installing the retainer, check that the No. 1 fuel evaporation tube is securely connected by pulling on it.

  1. Engage the 3 clamps and install the No. 1 fuel evaporation tube to the fuel tank.



10. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE


    A203001

  1. Install the No. 1 charcoal canister outlet hose onto the fuel tank vent tube assembly.
    Text in Illustration 
    *1
    		Yellow mark

    NOTICE:
    Install the No. 1 charcoal canister outlet hose with its yellow mark toward the rear of the vehicle.

  1. Clamp the No. 1 charcoal canister outlet hose.



11. INSTALL FUEL TANK WIRE


    A202859

  1. Install the fuel hose clamp to the fuel tank wire.



    A202883

  1. Connect the fuel tank wire connector to the fuel tank vent tube assembly.

  1. Engage the 3 clamps and install the fuel tank wire to the fuel tank.

    HINT:
    After connecting the fuel tank wire connector, check that the fuel tank wire is inserted securely.



12. INSTALL FUEL RETURN TUBE SUB-ASSEMBLY


    A202880E01

  1. Insert the fuel tank return tube into the fuel suction tube assembly plug and secure it with the tube joint clip.

    NOTICE:
    1. Check that there are no scratches or foreign objects on the connecting part.
    2. Check that the fuel return tube is inserted securely.
    3. Check that the tube joint clip is on the collar of the fuel return tube.
    4. After installing the tube joint clip, check that the fuel tank return tube is securely connected by pulling on it.



    A202882

  1. Engage the clamp and install the fuel tank return tube to the fuel tank.



13. INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY


    A202878E01

  1. Insert the fuel tank main tube into the fuel suction tube assembly plug and secure it with the tube joint clip.

    NOTICE:
    1. Check that there are no scratches or foreign objects on the connecting part.
    2. Check that the fuel tank main tube is inserted securely.
    3. Check that the tube joint clip is on the collar of the fuel tank main tube.
    4. After installing the tube joint clip, check that the fuel tank main tube is securely connected by pulling on it.



    A202881

  1. Engage the clamp and install the fuel tank main tube to the fuel tank.



14. INSTALL FUEL TANK CUSHION


    A202873E01

  1. Install the No. 1 fuel tank cushions and the No. 2 fuel tank cushions at the locations indicated in the illustration.
    Text in Illustration 
    *1
    		No. 1 fuel tank cushion
    *2
    		No. 2 fuel tank cushion



15. INSTALL FUEL TANK ASSEMBLY


    A202990

  1. Clean and degrease the bolt holes.

  1. Set the fuel tank on the engine lifter.

  1. Slowly raise the engine lifter and install the fuel tank onto the vehicle.

    NOTICE:
    Make sure that the fuel tank does not fall.



    A199515E01

  1. Tighten the 4 bolts in the sequence shown in the illustration, and secure the 2 fuel tank bands and the fuel tank.

    Torque:
    39 N*m{ 400 kgf*cm , 29 ft.*lbf }



16. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY


    A202876

  1. Connect the fuel return tube sub-assembly.



17. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    A202875E01

  1. Line up the pipe and connector and push them together until a "click" sound is heard.

  1. Push the checker into lock it.

    NOTICE:
    1. Check that there are no scratches or foreign objects on the connecting part.
    2. Check that the fuel tank main tube is inserted securely.
    3. After installing the checker, check that the fuel tank main tube is securely connected by pulling on it.



18. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY


    A199566E01

  1. Connect the inlet tube to the fuel tank assembly and lock it by pushing in the retainer.

    NOTICE:
    1. Check that there are no scratches or foreign objects on the connecting part.
    2. Check that the inlet tube is inserted securely.
    3. After installing the retainer, check that the inlet tube is securely connected by pulling on it.

    HINT:
    1. Insert the inlet tube until a "click" sound is heard.
    2. The quick connector cannot be locked when the tube is not inserted securely.



    A199565E01

  1. Connect the fuel tank breather tube to the fuel tank assembly and lock it by pushing in the retainer.

    NOTICE:
    1. Check that there are no scratches or foreign objects on the connecting part.
    2. Check that the breather tube is inserted securely.
    3. After installing the retainer, check that the breather tube is securely connected by pulling on it.

    HINT:
    The quick connector cannot be locked when the tube is not inserted securely.



19. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    A202947E01

  1. Connect the No. 1 charcoal canister outlet hose.
    Text in Illustration 
    *1
    		Yellow mark

    NOTICE:
    1. Install the No. 1 charcoal canister outlet hose with its yellow mark toward the rear of the vehicle.
    2. After connecting the fuel tank breather tube and No. 1 charcoal canister outlet hose, check that the evaporation vent tube clamp is securely connected by pulling on it.



20. INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY


    A199505

  1. Engage the claw and install the No. 1 fuel tank protector with the 2 clips and 4 nuts.

    Torque:
    5.5 N*m{ 56 kgf*cm , 49 in.*lbf }



21. CONNECT FUEL TANK WIRE


    A199504

  1. Pull the fuel tank wire through the floor, install the grommet in the floor, and connect the fuel tank wire connector.



22. ADD FUEL

  1. Open the fuel tank cap to add fuel.



23. BLEED AIR FROM FUEL SYSTEM
(Click here)


24. INSPECT FOR FUEL LEAK

  1. Connect an intelligent tester to the DLC3.

  1. Turn the ignition switch to ON.

  1. Turn the tester on.

  1. Enter the following menus: Powertrain / Engine / Active Test.

  1. Perform the Active Test.

    Intelligent Tester Display
    		Test Details
    		Control Range
    		Diagnostic Notes
    Test the Fuel Leak
    		Pressurize common rail internal fuel pressure, and check for fuel leaks
    		Stop/Start
    		Perform inspection of the high pressure fuel system.
    Test is possible when the following conditions are met:
    1. Warmed up engine.
    2. Vehicle is stopped.
    3. Battery voltage is 12 V or more.
    4. PM regeneration is not operating.
    5. Engine speed is less than 4000 rpm.
    Results of real-vehicle check:
    1. Engine Speed: 2702 rpm
    1. Fuel Pressure: 108570 kPa
    1. Target Common Rail Pressure: 105500 kPa
    1. Target Pump SCV Current: 1.2 A
    1. MAP: 127 kPa
    1. MAF: 28 g/sec.