Installation [09/2015 - ]: Procedure

INSTALL FUEL TANK CUSHION

Install the 5 tank cushions and fuel tank protector.

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Install the 3 tank cushions.

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INSTALL FUEL TANK VENT HOSE SUB-ASSEMBLY

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1. Install the vent hose to the fuel tank.
  1. Align the fuel tank vent hose connector with the pipe, then push in the fuel tank vent hose connector until the retainer makes a "click" sound to install the fuel tank vent hose to the fuel tank.
    NOTE:
    Check that there are no scratches or foreign objects around the connected part of the fuel tank vent hose connector and pipe before this procedure.
    
    After connecting the fuel tank vent hose, check that the fuel tank vent hose is securely connected by pulling the fuel tank vent hose connector.
INSTALL NO. 2 FUEL TANK PROTECTOR

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1. Install the clamp to the fuel tank.
2. Install the bolt and clip and fuel tank protector to the fuel tank.

INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

Install the fuel hose clamp.

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Install the fuel tank main tube to the fuel tank with the 6 clamps.

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INSTALL FUEL SENDER GAUGE ASSEMBLY

Install a new gasket and sender gauge to the fuel tank with the 5 screws.

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

INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Apply a light coat of gasoline to a new gasket, and install it to the fuel tank.

Connect the fuel hose, and install the fuel suction with pump and gauge tube.

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NOTE:

Be careful not to bend the arm of the fuel sender gauge.
When connecting the fuel hose, do not forcibly pull the hose.

Install the lower fuel tank protector and fuel tank vent tube set plate with the 8 bolts.

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

HINT:

Align the protrusion of the set plate with the cutout of the fuel suction pump and gauge.

INSTALL FUEL TANK ASSEMBLY

Set the fuel tank on a engine lifter.
Raise the engine lifter so that the fuel tank breather tube can be connected.
HINT:

Raise the engine lifter slowly.

Connect the fuel tank breather tube.

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NOTE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

HINT:

Push the parts together firmly until a "click" sound is heard.

Connect the fuel vent hose.

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NOTE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

HINT:

Push the parts together firmly until a "click" sound is heard.

Slowly raise the engine lifter, and install the 2 fuel tank bands with the 4 bolts.

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

NOTE:

Do not allow the fuel tank to contact the vehicle, especially the differential.
Make sure that the fuel tank is free from the fuel tank vent hose.

Connect the filler pipe hose to the fuel tank.

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Tighten the clamp.

Connect the fuel tank main tube.

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NOTE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

HINT:

Push the parts together firmly until a "click" sound is heard.

Connect the fuel tank return vent tube.

NOTE:

Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.
After the connection, check if the connectors and pipes are securely connected by trying to pull them apart.

HINT:

Push the parts together firmly until a "click" sound is heard.

INSTALL FUEL TANK PROTECTOR SIDE BRACKET

Install the protector side bracket with the 2 bolts.

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

INSTALL FUEL TANK FILLER PIPE PROTECTOR

Attach the 2 clips and protector.

Install the 2 nuts.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
(Refer to INSTALLATION [09/2015 - ] )
INSTALL REAR FLOOR SERVICE HOLE COVER

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1. Connect the fuel sender gauge connector.
2. Install the service hole cover with new butyl tape.

INSTALL FUEL TANK MAIN AND RETURN TUBE

Install the fuel tank main tube and fuel tank return vent tube with the 2 tube joint clips.

NOTE:

Check that there are no scratches or foreign objects on the connecting parts.
Check that the fuel tube joint is inserted securely.
Check that the tube joint clips are on the collars of the fuel tube joints.
After installing the tube joint clips, check that the fuel tube joints have not been pulled off.

INSTALL REAR FLOOR NO. 2 SERVICE HOLE COVER

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1. Connect the connector.
2. Install the service hole cover with new butyl tape.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [09/2015 - ] ).
INSTALL COWL TOP VENTILATOR LOUVER RH
Refer to PROCEDURE - Step 15
INSPECT FOR FUEL LEAK
Refer to PROCEDURE - Step 1
INSTALL REAR NO. 1 AND NO. 2 SEAT ADJUSTER ASSEMBLY
- for Poser Seat:
  (Refer to INSTALLATION [09/2015 - ] )
- for Ottoman:
  (Refer to INSTALLATION [09/2015 - ] )
INSTALL REAR SEAT CUSHION ASSEMBLY (for Fixed Type)
(Refer to INSTALLATION [09/2015 - ] )