Fuel Tank (S80): Installation
- Put fuel tank on lifting table. Raise high enough so lines and plastic pipes between carbon filter container and EVAP valve can be attached. Connect lines to right level sensor. Route electrical wiring to passenger compartment through floor.NOTE: Use NEW hose clamps when putting fuel tank into position.
- Lift tank completely into position. Ensure no lines or wires are trapped. Install fuel filler pipe and bleed pipe on tank. Twist hose clamps around so tightening screw is accessible. Do not tighten. Install ABS wiring into clips. Tighten tank retaining strap bolts to specification. See TORQUE SPECIFICATIONS . See Fig 1. Install fuel filter and console.
- Install center and front mounting screws for heat shield. Install parking brake cables on wheel units. Tighten parking brake mounts (in subframe) to specification. See TORQUE SPECIFICATIONS . Install cable mount into track rods. Press guide sleeves for parking brake cables into place on wheel units. Use silicone grease on "O" rings. Install expander onto cable. Press mounting together to lock cable in place. Install expander between brake shoes and fit return spring. Check function of parking brake. See Fig 2.
- Fit brake rotors and calipers. Tighten brake disc locating pin and brake caliper bolt to specification. See TORQUE SPECIFICATIONS .
- Install plastic pipe with large connector from fuel tank onto EVAP canister. Fitting will click when fully engaged. Install heat deflector plate over rear muffler. Install plastic nuts and pop rivets.
- Install exhaust system using new flange gaskets. Tighten bolts to specification. See TORQUE SPECIFICATIONS . See Figure.
- Fit rear wheels. Tighten lug nuts to specification. See TORQUE SPECIFICATIONS . Lower vehicle.
- Connect electrical connectors on right and left pump units from inside vehicle. Fit cover over level sensors. Ensure wiring is routed properly. Fit interior trim panels.