FUEL SENDER GAUGE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. A004PAV

      Install the fuel sender gauge assembly by sliding it downward.

    2. Attach the wire harness clamp.

      Note

      Do not damage the wire harness.

    3. Connect the fuel sender gauge assembly connector.

  2. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. Apply a light coat of diesel fuel to a new gasket and install the gasket to the fuel tank assembly.

    2. Install the fuel tank vent tube sub-assembly to the fuel tank assembly.

      Note

      Make sure that the fuel sender gauge assembly arm does not bend.

    3. A004TOTE03
      Text in Illustration
      *a Notch
      *b Protrusion

      Align the protrusions of the fuel tank vent tube sub-assembly with the notches of the fuel tank assembly.

  3. INSTALL FUEL PUMP GAUGE RETAINER


    1. A004TKRE03
      Text in Illustration
      *a Center Point of Fuel Pump Gauge Retainer
      *b SST (Plate)

      Adjust the position of SST (claw) so that the hole in SST (plate) for installing SST (handle) is in the center of the fuel pump gauge retainer.

      SST
      09808-14030
      09808-01070   ( 09808-01010, 09808-01020, 09808-01030, 09808-01050 )
    2. A004T52E02
      Text in Illustration
      *a Start Mark (Fuel Tank Assembly Side)
      *b Start Mark (Fuel Pump Gauge Retainer Side)
      A004NPW Front of Vehicle

      Align the start marks on the fuel pump gauge retainer and fuel tank assembly as shown in the illustration.

      Note

      Replace the fuel pump gauge retainer with a new one if not installed properly.

    3. A004RNXE01
      Text in Illustration
      *1 Fuel Pump Gauge Retainer
      *a CORRECT
      *b INCORRECT
      *c SST (Claw)

      Temporarily install SST (plate) and SST (claw) to the fuel pump gauge retainer.

      Note

      Install SST (claw) to the correct location.

    4. A004T1JE01
      Text in Illustration
      *a SST (Plate)
      *b SST (Claw)
      *c SST (Bolt)
      A004NPW Press

      Press SST (claw) against the rib of the fuel pump gauge retainer and tighten SST (bolt).

    5. A004P7YE02
      Text in Illustration
      *a SST (Plate)
      *b Start Mark (Fuel Pump Gauge Retainer Side)
      *c Worker A
      *d Worker B
      *e Approximately 180°
      A004NPW Press Down
      A004NAK Slowly Rotate
      A004PZH Front of Vehicle

      While one person presses down to prevent the fuel pump gauge retainer and the fuel tank vent tube sub-assembly from rotating together, the other person should firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten it by rotating it approximately 180°.

      CAUTION:

      Make sure not to pinch your hands with SST.

      Note


      • Be careful not to apply excessive downward force to SST, as this may damage the fuel tank vent tube sub-assembly or fuel tank assembly.

      • Turning SST at an angle may cause it to slip off of the fuel pump gauge retainer, so make sure SST is horizontal when turning it.

      • To prevent damage to parts, do not turn SST too vigorously.

      • If SST slips off of the fuel pump gauge retainer, loosen SST (bolt) and install SST again.

    6. Quickly and firmly press down on the part of the fuel pump gauge retainer closest to the front side of the vehicle so that it no longer rises up as shown in the illustration.

      A004SIDE02
      Text in Illustration
      *1 Fuel Pump Gauge Retainer *2 Fuel Tank Assembly
      *a SST (Plate) - -
      A004NPW Press Quickly and Firmly A004NAK Fuel Pump Gauge Retainer Rise Up Area
      A004PZH Front of Vehicle - -

      Tech Tips


      • If the fuel pump gauge retainer cannot be properly pressed down due to the position of SST, set SST in a different position.

      • When pressing down the fuel pump gauge retainer, there will be a sound or feeling of parts contacting and pressing together when the fuel pump gauge retainer is fully pressed down, and at this point it will stop rising up.

    7. A004PARE02
      Text in Illustration
      *a SST (Plate)
      *b Start Mark (Fuel Pump Gauge Retainer Side)
      *c Start Mark (Fuel Tank Assembly Side)
      *d Worker A
      *e Worker B
      *f Rotate to Start Mark on Fuel Tank Assembly
      A004NPW Press Down
      A004NAK Slowly Rotate
      A004PZH Front Side of Vehicle

      While one person presses down to prevent the fuel pump gauge retainer and the fuel tank vent tube sub-assembly from rotating together, the other person should slowly rotate SST (plate) and tighten the fuel pump gauge retainer until it reaches the start mark on the fuel tank assembly.

      CAUTION:

      Make sure not to pinch your hands with SST.

    8. Check the tightening condition of the fuel pump gauge retainer.


      1. A004MVOE02
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Assembly
        *a Measurement Location
        *b Vernier Caliper
        A004NPW Front of Vehicle

        Using a vernier caliper, measure the upper surface of the fuel tank assembly in the 3 locations shown in the illustration.

        Specification
        Difference between the 3 measured values is within 3.0 mm (0.118 in.).

        Note

        If the difference between measurements is approximately 6.0 mm (0.236 in.), the threads are cross-threaded by one row (6.0 mm (0.236 in.), so remove and reinstall the fuel pump gauge retainer.

    9. Install SST (handle) to SST (plate).

    10. A004ROOE02
      Text in Illustration
      *a SST (Handle)
      *b SST (Plate)
      *c Start Mark (Fuel Pump Gauge Retainer Side)
      *d Worker A
      *e Worker B
      *f Fully Tightened Position
      A004NPW Hold Down
      A004NAK Slowly Rotate
      A004PZH Front Side of Vehicle

      To make sure SST does not separate from the fuel pump gauge retainer, one person should hold down the center of SST from above while at the same time both people slowly rotate SST (handle) and slowly tighten the fuel pump gauge retainer until it reaches the fully tightened position.

  4. INSTALL TANK SUCTION TUBE SUPPORT


    1. Attach the 2 claws to install the tank suction tube support.

    2. A004P95

      Install the fuel tube clamp.

      Note

      Securely install the fuel tube clamp by pushing it until it makes a clicking sound.

  5. CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. Push the fuel tank return tube sub-assembly into the plug of the fuel tank vent tube sub-assembly, and then install the tube joint clip.

      A004P4ZE01

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tank return tube sub-assembly is inserted securely.

      • Check that the tube joint clip is on the collar of the fuel tank return tube sub-assembly.

      • After installing the tube joint clip, check that the fuel tank return tube sub-assembly cannot be pulled off.

      • Perform this step by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tank Return Tube Sub-assembly
      *3 O-Ring
      *4 Collar
      *5 Nylon Tube
      *a CORRECT
      *b INCORRECT

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. Push the fuel tank main tube sub-assembly into the plug of the fuel tank vent tube sub-assembly, and then install the tube joint clip.

      A004NO8E01

      Note


      • Check that there are no scratches or foreign objects on the connecting parts.

      • Check that the fuel tank main tube sub-assembly is inserted securely.

      • Check that the tube joint clip is on the collar of the fuel tank main tube sub-assembly.

      • After installing the tube joint clip, check that the fuel tank main tube sub-assembly cannot be pulled off.

      • Perform this step by hand. Do not use any tools.

      • Do not forcibly bend or twist the nylon tube.

      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tank Main Tube Sub-assembly
      *3 O-Ring
      *4 Collar
      *5 Nylon Tube
      *a CORRECT
      *b INCORRECT

  7. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. Connect the fuel sender gauge assembly connector.

    2. Install the rear floor service hole cover with new butyl tape.

      Note

      Be careful that the rear floor service hole cover does not overlap the protrusions of the floor panel when installing.

  8. BLEED AIR FROM FUEL SYSTEM

    Click here

  9. INSPECT FOR FUEL LEAK

    Click here

  10. INSTALL REAR SEAT CUSHION ASSEMBLY