Installation of New Tank

D. INSTALLATION OF NEW TANK

1. Raising right side of the fuel tank, install new fuel tank into the vehicle.





2. Secure right and left fuel tank bands.

Torque: 375 kg.cm. (27 ft.lb., 37 N-m)

Note: Make sure that rubber protectors are correctly installed between the tank and tank bands.





3. Connect and secure fuel main and return hoses to the fuel main tube sub-assy. at the right front corner of the fuel tank.

Note: Make sure that the hoses do not contact each other and/or other parts.





4. Connect fuel inlet hose to the fuel tank and secure hose clamps.

5. Connect 5 fuel hoses to fuel tube connector and secure them with clips.

6. Install 2 front fuel hoses (out of 5) into the clamps on the body.

7. Install fuel hose protector.

Torque: 65 kg.cm. (4.7 ft.lb., 6.4 N-m)





8. Using new self-lock nuts contained in the fuel tank service kit (P/N 04001-04160) and 2 bolts, install rear stabilizer together with the links and brackets, if the vehicle is equipped with a rear stabilizer.

Torque: For bolts 130 kg.cm. (9 ft.lb., 13 N-m) For self-lock nuts 185 kg.cm. (13 ft.lb., 18 N-m)





9. Install crossmember No. 5 together with the spare wheel carrier.

Torque: 400 kg.cm. (29 ft.lb., 39 N-m)





10. Connect fuel sender gage wire.

11. Install rear floor service hole cover.

12. Install rear floor mat (and trim plate).





13. Refill fuel tank with drained fuel plus an additional 5 gallons and install fuel tank cap.

Note: Do not insert the fuel hose too deeply into the tank inlet.





14. Reconnect negative battery cable.





15. Start engine and check for fuel leaks and proper operation.





16. Check fuel gage for correct operation.





17. Reinstall spare wheel.

Torque: 340 kg.cm. (25 ft.lb., 33 N-m)





18. Reset the clock and if the vehicle is equipped with a radio with electronic tuner, reprogram the preset radio stations.