RM38N0EC _51 Engine / Hybrid System _111793 M20C-FKS, M20D-FKS FUEL _0504184 FUEL TANK A

M20C-FKS, M20D-FKS FUEL  FUEL TANK  INSTALLATION  


PROCEDURE

Hide 77654A 1.INSTALL NO. 4 FUEL TANK CUSHION

a.

Install 2 new No. 4 fuel tank cushions to the fuel tank assembly.


Hide 77653A 2.INSTALL NO. 3 FUEL TANK CUSHION

a.

Install a new No. 3 fuel tank cushion to the fuel tank assembly.


Hide 77652A 3.INSTALL NO. 2 FUEL TANK CUSHION

a.

Install a new No. 2 fuel tank cushion to the fuel tank assembly.


Hide 77651A 4.INSTALL NO. 1 FUEL TANK CUSHION

a.

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


Hide 77016H 5.INSTALL FUEL RETURN VENT TUBE SUB-ASSEMBLY

a.
A499868C01
1.823,1.885 1.823,1.625 true 1.76,1.896 1.969,2.104 0.208,0.208 10 false *a
*1 Fuel Return Vent Tube Sub-assembly
V100135

Front of the Vehicle


Imstall the fuel return vent tube sub-assembly to the fuel tank assembly.

NOTICE:

Make sure to correctly assemble the fuel return vent tube sub-assembly as shown in the illustration. If assembled incorrectly, the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) may catch on the fuel return vent tube sub-assembly resulting in incorrect operation of the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) and an incorrect value being displayed on the fuel gauge.



Hide 77209C 6.INSTALL FUEL TANK MAIN TUBE SUB-ASSEMBLY

a.

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


Hide 77100 7.INSTALL FUEL TANK ASSEMBLY

CAUTION:
A344817

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.


a.

Set the fuel tank assembly on an engine lifter.

NOTICE:

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



b.

Using the engine lifter, slowly raise the fuel tank assembly, and then temporarily install the fuel tank assembly and 2 fuel tank band sub-assemblies with the 4 bolts.

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.




c.
A476838
0.49,1.979 0.635,2.167 0.146,0.188 10 true 1 0.521,0.021 0.677,0.219 0.156,0.198 10 true 2 2.781,0.021 2.938,0.219 0.156,0.198 10 true 3 2.885,1.938 3.042,2.135 0.156,0.198 10 true 4

Tighten the 4 bolts in the order shown in the illustration.

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


d.
A434521
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 0.031,0.031 0.26,0.25 0.229,0.219 10 true *a 0.063,2.427 0.281,2.625 0.219,0.198 10 true *b 2.51,1.917 2.729,2.104 0.219,0.188 10 true *c 1.188,4.479 1.406,4.667 0.219,0.188 10 true *c 1.156,1.344 1.479,1.531 0.323,0.188 10 true SST 2.115,3.885 2.438,4.073 0.323,0.188 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 sub-assembly.

SST
09961-00950  

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

HINT:
·

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

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

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 77210 8.CONNECT FUEL TANK FILLER PIPE ASSEMBLY

a.

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION


Hide 9.CONNECT FUEL TANK BREATHER TUBE

a.

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION


Hide 77209C 10.CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY

a.

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION


Hide 11.CONNECT FUEL TANK EVAP/VENT TUBE SUB-ASSEMBLY

a.

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION


b.

Engage the clamp.


Hide 77606 12.INSTALL NO. 1 FUEL TANK PROTECTOR SUB-ASSEMBLY

a.

Install the No. 1 fuel tank protector sub-assembly to the fuel tank assembly with the 4 clips.


Hide 77606C 13.INSTALL NO. 2 FUEL TANK PROTECTOR

a.

Install the No. 2 fuel tank protector with the nut.

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


Hide 16.ADD FUEL

Hide 58398F 19.INSTALL NO. 1 FLOOR UNDER COVER

a.

Tighten the clip to install the No. 1 floor under cover to the vehicle body.


b.

Install the 3 clips and 2 bolts.

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


Hide 58165C 20.INSTALL FRONT FLOOR COVER RH

a.

Tighten the 3 clips to install the front floor cover RH to the vehicle body.


b.

Install the 2 clips, 2 bolts and 4 screws.

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


Hide 58399D 21.INSTALL NO. 2 FLOOR UNDER COVER

a.

Tighten the 4 clips to install the No. 2 floor under cover to the vehicle body.


b.

Install the 3 clips and 2 bolts.

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


Hide 58166A 22.INSTALL FRONT FLOOR COVER LH

a.

Tighten the 3 clips to install the front floor cover LH to the vehicle body.


b.

Install the 3 clips, 2 bolts and 5 screws.

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