FUEL SENDER GAUGE ASSEMBLY INSTALLATION

INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Install the fuel sender gauge by sliding it downward.
2. Attach the wire harness clamp.
3. Connect the fuel sender gauge connector.
INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Gasket
  
  Apply a light coat of diesel fuel to a new gasket and install the gasket to the fuel tank.
2. Install the fuel tank vent tube to the fuel tank.
  
  Note
  
  Make sure that the fuel sender gauge arm does not bend.
3. Text in Illustration
  
  *1 Notch
  
  *2 Protrusion
  
  Align the protrusions of the fuel tank vent tube with the notches of the fuel tank.
INSTALL FUEL PUMP GAUGE RETAINER
1. While holding the fuel tank vent tube by hand to prevent it from tilting, align the starting marks on the fuel pump gauge retainer and fuel tank and tighten the fuel pump gauge retainer 180° by hand.
  Tech Tips
  
  Check that there is no damage, dents, foreign matter or other defect on the threads of the fuel tank.
  
  The diameter of a supplied fuel pump gauge retainer is larger than that of the factory-installed retainer, anticipating that the fuel tank swells and expands over time. If the diameter of the factory-installed retainer is too small to reinstall, use a supplied fuel pump gauge retainer.
2. Using a 6 mm socket, install SST to the fuel pump gauge retainer.
  
  SST
  
  09808-14020
  Tech Tips
  
  Engage the claws of SST securely with the fuel pump gauge retainer ribs to secure SST.
  
  Install SST while pressing the claws of SST toward the fuel pump gauge retainer (toward the center of SST).
3. Tighten the fuel pump gauge retainer approximately 270° so that the start mark on the retainer comes within the range shown in the illustration.
  Note
  
  Do not use any tools other than those specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.
  
  Tighten the retainer by turning it clockwise while holding SST down. Do not allow the protrusions of the fuel tank vent tube to slip out of their notches on the fuel tank.
  Tech Tips
  
  The ribs on the fuel pump gauge retainer can be fitted into the tips of SST.
INSTALL TANK SUCTION TUBE SUPPORT
1. Attach the 2 claws to install suction tube support.
2. Install the tube.
  
  Note
  
  Securely install the tube by pushing on it until it makes a clicking sound.
CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY
1. Push the fuel tube joint into the plug of the fuel tank vent tube, and then install the tube joint clip.
  Note
  
  Check that there are no scratches or foreign objects on the connecting parts.
  
  Check that the fuel tube joint is inserted securely.
  
  Check that the tube joint clip is on the collar of the fuel tube joint.
  
  After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.
CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY
1. Push the fuel tube joint into the plug of the fuel tank vent tube, and then install the tube joint clip.
  Note
  
  Check that there are no scratches or foreign objects on the connecting parts.
  
  Check that the fuel tube joint is inserted securely.
  
  Check that the tube joint clip is on the collar of the fuel tube joint.
  
  After installing the tube joint clip, check that the fuel tube joint cannot be pulled off.
INSTALL REAR FLOOR SERVICE HOLE COVER
1. Connect the sender gauge 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.
BLEED AIR FROM FUEL SYSTEM
1. Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.
  Note
  
  Hand pump pumping speed: Max. 2 strokes/ sec.
  
  The hand pump must be pushed with a full stroke during pumping.
  
  When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
  
  If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
  
  If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
  
  If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.
2. Start the engine.
  Note
  - Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
  - Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
  - Use a fully-charged battery.
  1. When the engine can be started, proceed to the next step.
  2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
3. Turn the ignition switch off.
4. Connect the intelligent tester to the DLC3.
5. Turn the ignition switch to ON and turn the intelligent tester on.
6. Clear the DTCs Click here.
7. Start the engine.*1
8. Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2
9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3
10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.
  
  Tech Tips
  
  When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.
11. Enter the following menus: Powertrain / Engine and ECT / DTC.
12. Read Current DTCs.
  1. When no DTCs are output, the air bleeding is completed.
  2. If any DTCs are output, proceed to the next step.
13. Clear the DTCs Click here.
14. Repeat steps *1 to *3.
15. Enter the following menus: Powertrain / Engine and ECT / DTC.
16. Read Current DTCs.
  
  OK
  
  No DTCs are output.

Text in Illustration
*1	Gasket

Text in Illustration
*1	Notch
*2	Protrusion

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Tech Tips

Using the intelligent tester to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.

Perform Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Start the engine.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine / Active Test.

Perform the Active Test.

Tester Display	Test Part	Control Range	Diagnostic Notes
Test the Fuel Leak	Pressurizes common rail internal fuel pressure, and checks for fuel leaks	Stop/Start	Performs inspection of the high pressure fuel system. Engine Speed: 2050 rpm Fuel Pressure: 172000 kPa Target Common Rail Pressure: 176000 kPa Target Pump SCV Current: 1400 mA MAP: 176 kPa MAF: 39 g/sec.

Tester Display

Test Part

Control Range

Diagnostic Notes

Test the Fuel Leak

Pressurizes common rail internal fuel pressure, and checks for fuel leaks

Stop/Start

Performs inspection of the high pressure fuel system.

Engine Speed: 2050 rpm
Fuel Pressure: 172000 kPa
Target Common Rail Pressure: 176000 kPa
Target Pump SCV Current: 1400 mA
MAP: 176 kPa
MAF: 39 g/sec.

INSTALL REAR SEAT CUSHION ASSEMBLY
1. for Sedan:
  
  Install the rear seat cushion assembly Click here.
2. for Wagon:
  
  Install the rear seat cushion assembly Click here.