Fuel Tank: Installation

1. Install the No. 2 fuel tank protector to the fuel tank assembly.
   Fig 1: Identifying No. 2 Fuel Tank Protector

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1. Install 11 new fuel tank cushions shown in the illustration.
   Fig 2: Identifying Fuel Tank Cushions

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1. Connect the fuel tank vent hose to the fuel tank.
   Fig 3: Connecting Fuel Tank Vent Hose To Fuel Tank

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1. Install the fuel tank to filler pipe hose to the fuel tank with the clamp.
2. Tighten the hose clamp bolt.
   Fig 4: Locating Hose Clamp Bolt

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1. Install the edge protector with the 2 clamps.
   Fig 5: Identifying Edge Protector And Clamps

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2. Install a fuel tank main tube and fuel tank return vent tube with the clamp.

1. Install a new gasket to the No. 1 fuel tank breather tube sub-assembly.
   Fig 6: Locating Fuel Tank Main Tube And Fuel Tank Return Vent Tube Clamp

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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 7: Locating No. 1 Fuel Tank Breather Tube Sub-Assembly Bolts

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1. Set a engine lifter to the fuel tank and lift it up.
2. Install the 2 fuel tank bands with the 4 bolts.

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

   Fig 8: Locating Fuel Tank Bands Bolts

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1. Connect the fuel tank to canister 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 9: Connecting Fuel Tank To Canister Tube Sub-Assembly

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1. Connect the No. 3 fuel hose sub-assembly with the clip.
2. Connect the fuel hose clamp.
   Fig 10: Connecting No. 3 Fuel Hose Sub-Assembly With Clip

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

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1. Connect the fuel tank main 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 objects on the connected part.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
        Fig 12: Connecting Fuel Tank Main Tube

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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 objects on the connected part.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
        Fig 13: Connecting Fuel Tank Return Vent Tube

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1. Connect the 4 clamps.
2. Connect the 2 parking brake cables 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 14: Locating Parking Brake Cables Bolts

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1. Install the suspension member brace lower LH with the 4 bolts.

   Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

   Fig 15: Locating Suspension Member Brace Lower LH Bolts

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1. Install the suspension member brace lower RH with the 4 bolts.

   Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

   Fig 16: Locating Suspension Member Brace Lower RH Bolts

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HINT:

Installation procedure of the No. 1 differential support protector is the same as that of the No. 2 differential support protector.

HINT:

See INSTALLATION .

HINT:

See INSTALLATION .

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

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

   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.

1. Perform initialization (See INITIALIZATION ).

   HINT:

   Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.

   Fig 19: Identifying Service Hole Cover

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