Fuel Lid (Wagon)

REMOVAL

HINT: A bolt without a torque specification is shown in the standard bolt chart.

1. REMOVE REAR SEAT CUSHION
2. REMOVE SIDE SEATBACK ASSEMBLY
3. REMOVE REAR SEAT FLOOR BOARD NO. 4
a. Remove the seat back board carpets.
b. Remove the 2 bolts and rear floor board.

4. REMOVE DECK FLOOR BOX FRONT
a. Remove the 2 bolts and the 2 rope hook assemblies.
b. Remove the 2 bolts and 2 tether anchor brackets.
c. Remove the restraint seat tether anchor cover.
d. Remove the deck floor box.

5. REMOVE DECK BOARD NO. 2
6. REMOVE REAR FLOOR BOARD NO. 2
7. REMOVE REAR FLOOR BOARD NO. 3
8. REMOVE TONNEAU COVER ASSEMBLY




9. REMOVE REAR FLOOR FINISH PLATE
a. Remove the 2 bolts and the 2 rope hook assemblies.
b. Remove the 3 clips.
c. Using a screwdriver, remove the rear floor finish plate.

HINT: Tape the screwdriver tip before use.




10. REMOVE DECK TRIM SIDE PANEL ASSEMBLY
a. Remove the 2 bolts and 2 floor hooks.
b. Remove the screw, bolt and clip.
c. Using a screwdriver, remove the deck trim side panel assembly, then disconnect the connector.

HINT: Tape the screwdriver tip before use.




11. REMOVE ROOF SIDE INNER GARNISH
Using a screwdriver, remove the roof side inner garnish.

HINT: Tape the screwdriver tip before use.




12. REMOVE FUEL LID LOCK CONTROL
a. Rotate the fuel lid lock to the right to disengage the lock, then pull it out.




b. Rotate the retainer to the left to disengage the lock, then pull it out.




13. REMOVE FUEL FILLER SHIELD
a. Remove the 2 rings from the fuel filler shield.
b. Remove the fuel tank cap and shield.

CAUTION: Always keep the tank cap closed when it is not required to be open. Keep open fire away during the operation.

c. Install the fuel tank cap quickly.




14. REMOVE FUEL TANK CAP HANGER
Pull up the fuel tank cap hanger to remove it.

15. REMOVE FUEL FILLER OPENING LID LOCK RETAINER
Remove the nut and fuel filler opening lid lock retainer.




16. REMOVE FUEL LID OPENING SPRING
Insert a screwdriver between the spring and fuel filler opening lid to remove the spring as shown in the illustration.

HINT: Tape the screwdriver tip before use.




17. REMOVE FUEL FILLER OPENING LID
a. Using a drill, drill out the rivet heads.
b. Remove the fuel filler opening lid.

INSTALLATION




1. INSTALL FUEL FILLER OPENING LID
Using a riveter, install the fuel filler opening lid with the 2 rivets to the body.












NOTE:
- Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.
- Do not tilt the riveter when fastening the rivet to the material to avoid loose fitting.
- Do not allow gap spacing between the rivet head and the material.
- Do not allow gap spacing between the materials.

2. INSTALL FUEL FILLER OPENING SPRING




3. INSTALL FUEL FILLER OPENING LID LOCK RETAINER
Install the fuel filler opening lid lock retainer with the nut.

4. INSTALL FUEL TANK CAP HANGER




5. INSTALL FUEL FILLER SHIELD
a. Remove the fuel tank cap.
b. Install the fuel filler shield to the body, and put the fuel tank cap back immediately.
c. Install the fuel tank cap quickly.

CAUTION: Always keep the tank cap closed when it is not required to be open. Keep open fire away during the operation.

d. Install the 2 rings to the fuel filler shield as shown in the illustration.




6. INSTALL FUEL LID LOCK CONTROL
a. Install the retainer to the body from the outside of the vehicle and rotate it right to lock.




b. Insert the fuel lid lock control to the retainer and rotate it to the left to lock.




7. INSTALL ROOF SIDE INNER GARNISH




8. INSTALL DECK TRIM SIDE PANEL ASSEMBLY
a. Install the deck trim side panel assembly then connect the connector.
b. Install the screw, bolt and clip.
c. Install the 2 floor hooks with the 2 bolts.




9. INSTALL REAR FLOOR FINISH PLATE
a. Install the rear floor finish plate.
b. Install the 3 clips.
c. Install the 2 rope hook assemblies with the 2 bolts.

10. INSTALL TONNEAU COVER ASSEMBLY
11. INSTALL REAR FLOOR BOARD NO. 3
12. INSTALL REAR FLOOR BOARD NO. 2
13. INSTALL DECK BOARD NO. 2
14. INSTALL DECK FLOOR BOX FRONT
a. Install the deck floor box.
b. Install the 2 tether anchor brackets with the 2 bolts.

Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)

c. Install the restraint seat tether anchor cover.
d. Install the 2 rope hook assemblies with the 2 bolts.

15. INSTALL REAR SEAT FLOOR BOARD NO. 4
a. Install the rear floor board with the 2 bolts.
b. Install the seat back board carpets.

16. INSTALL SIDE SEAT BACK ASSEMBLY
17. INSTALL REAR SEAT CUSHION