RM36D0EC _51 Engine / Hybrid System _083060 M20D-FKS FUEL _0406681 FUEL TANK A

M20D-FKS FUEL FUEL TANK INSTALLATION

PROCEDURE

Hide Display 77606 1.INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

Attach the 4 clips and install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly.

Hide Display 77651A 2.INSTALL NO. 1 FUEL TANK CUSHION

Install 2 new No. 1 fuel tank cushions to the fuel tank assembly.

Hide Display 77209C 3.INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

Attach the clamp and install the fuel tank main tube sub-assembly to the fuel tank assembly.

Hide Display 77100 4.INSTALL FUEL TANK ASSEMBLY

CAUTION:: The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

Set the fuel tank assembly on an engine lifter.

NOTICE:: Using height adjustment attachments and plate lift attachments, keep the fuel tank assembly horizontal.

2.813,1.833 2.969,2.021 0.156,0.188 10 true 1 0.521,1.958 0.677,2.146 0.156,0.188 10 true 2

Using the engine lifter, slowly raise the fuel tank assembly, and temporarily install the fuel tank assembly and 2 fuel tank band sub-assemblies with the 2 bolts in the order shown in the illustration.

NOTICE:: ·

Be careful not to drop the fuel tank assembly.

·

When installing the fuel tank assembly, tilt it slightly to prevent it from interfering with the surrounding parts.

2.844,0.021 3,0.219 0.156,0.198 10 true 1 2.823,1.823 2.979,2.021 0.156,0.198 10 true 2 0.385,0.042 0.531,0.24 0.146,0.198 10 true 3 0.531,1.969 0.667,2.135 0.135,0.167 10 true 4

Using SST, tighten the 4 bolts in the order shown in the illustration.

SST: 09961-00950

Torque:: Specified tightening torque:; 45 N*m (459 kgf*cm, 33 ft.*lbf)

HINT:

1.25,1.302 1.25,1.135 1.25,1.135 1.333,0.813 true 2.229,3.854 2.229,3.688 2.229,3.688 2.146,3.438 true 0.083,0.115 0.333,0.292 0.25,0.177 10 true *a 0.115,2.615 0.365,2.802 0.25,0.188 10 true *b 2.458,1.906 2.708,2.083 0.25,0.177 10 true *c 1.167,4.479 1.417,4.656 0.25,0.177 10 true *c 1.167,1.323 1.51,1.5 0.344,0.177 10 true SST 2.104,3.875 2.448,4.052 0.344,0.177 10 true SST

*a	LH Side
*b	RH Side
*c	Torque Wrench Fulcrum Length

Using SST, install the rear side of the fuel tank band.

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201910,999999,_V1,_083040,_0402303,RM100000001JHCH,

When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24.5 N*m (250 kgf*cm, 18 ft.*lbf)

Hide Display 5.CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY

Connect the fuel tank filler pipe sub-assembly to the fuel tank filler pipe assembly.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION202004,999999,_51,_083060,_0403631,RM100000001MUZU,

Hide Display 6.CONNECT FUEL TANK BREATHER TUBE

Connect the fuel tank breather tube to the fuel tank filler pipe assembly.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION202004,999999,_51,_083060,_0403631,RM100000001MUZU,

Hide Display 77209C 7.CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

Connect the fuel tank main tube sub-assembly to the fuel tube.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION202004,999999,_51,_083060,_0403631,RM100000001MUZU,

Hide Display 8.CONNECT FUEL TANK VENT TUBE

Attach the clamp and connect the fuel tank vent tube.

Connect the fuel tank vent tube to the fuel tank vent hose sub-assembly.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION202004,999999,_51,_083060,_0403631,RM100000001MUZU,

Hide Display 77606 9.INSTALL NO. 1 FUEL TANK PROTECTOR

Install the No. 1 fuel tank protector to the fuel tank band with the 2 nuts.

Torque:: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)

Hide Display 58398F 10.INSTALL NO. 1 FLOOR UNDER COVER

Install the No. 1 floor under cover to the body and tighten the nut.

Attach the 3 clips and install the 2 bolts.

Torque:: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide Display 58165C 11.INSTALL FRONT FLOOR COVER RH

Install the front floor cover RH to the body and tighten the 3 nuts.

Attach the 2 clips and install the 2 bolts and 4 screws.

Torque:: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide Display 58399D 12.INSTALL NO. 2 FLOOR UNDER COVER

Install the No. 2 floor under cover to the body and tighten the 4 nuts.

Attach the 3 clips and install the 2 bolts.

Torque:: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide Display 58166A 13.INSTALL FRONT FLOOR COVER LH

Install the front floor cover LH to the body and tighten the 3 nuts.

Attach the 3 clips and install the 2 bolts and 5 screws.

Torque:: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide Display 51420 14.INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

Click hereEngine / Hybrid System>M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_083059,_0403046,RM1000000029XAF_01_0292,

Hide Display 51441 15.INSTALL NO. 1 ENGINE UNDER COVER

Click hereEngine / Hybrid System>M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_083059,_0403046,RM1000000029XAF_01_0293,

Hide Display 53895B 16.INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

Click hereEngine / Hybrid System>M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_083059,_0403046,RM1000000029XAF_01_0331,

Hide Display 53896B 17.INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

Click hereEngine / Hybrid System>M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202304,999999,_51,_083059,_0403046,RM1000000029XAF_01_0330,

Hide Display 37100 18.INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY>INSTALLATION202004,999999,_52,_083070,_0403352,RM100000001MQF7,

Hide Display 17408 19.INSTALL TAIL EXHAUST PIPE ASSEMBLY

Click hereEngine / Hybrid System>M20D-FKS (INTAKE / EXHAUST)>EXHAUST PIPE>INSTALLATION202304,999999,_51,_083062,_0402933,RM1000000029QEF,

Hide Display 20.ADD FUEL

Hide Display 77020A 21.INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL PUMP (for High Pressure)>INSTALLATION202304,999999,_51,_083060,_0403639,RM100000002AALL,

Hide Display 77010 22.INSTALL FUEL TANK VENT TUBE ASSEMBLY

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SENDER GAUGE ASSEMBLY>INSTALLATION202304,999999,_51,_083060,_0403642,RM100000002AALR,

Hide Display 23.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Click hereGeneral>MAINTENANCE>M20D-FKS BATTERY>INSTALLATION202304,999999,_V1,_083136,_0403617,RM100000002A9CC_01_0015,

Hide Display 24. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

HINT:: When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.; Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART202304,202405,_V1,_083041,_0402304,RM100000002AJ9H,202405,202409,_V1,_083041,_0402304,RM100000002LTUF,202409,999999,_V1,_083041,_0402304,RM100000002NY03,