FUEL SENDER GAUGE ASSEMBLY INSTALLATION


  1. INSTALL FUEL TANK SUCTION TUBE GASKET


    1. A0118E2

      Install a new gasket to the fuel tank.

  2. INSTALL FUEL TANK VENT TUBE ASSEMBLY


    1. A011BVJ

      Engage the 2 claws and connect the fuel tank vent tube sub-assembly to the fuel tank vent tube assembly.

    2. A0118E0E01
      Text in Illustration
      *1 Arrows

      Rotate the fuel tank vent tube in the direction shown by the arrows, insert the sender gauge in the direction of the fuel tank gauge shown by the arrows, and then install the fuel tank vent tube assembly into the fuel tank.

      Note

      Do not bend the sender gauge arm.

  3. INSTALL FUEL PUMP GAUGE RETAINER


    1. A0118UDE01
      Text in Illustration
      *1 Cutout

      Align the protrusion of the fuel tank vent tube assembly with the cutouts of the fuel tank.

      Note

      Ensure that the fuel suction tube gasket is in the correct position.

    2. While holding the fuel tank vent tube assembly by hand, position the fuel pump gauge retainer and tighten it lightly by hand.

      Note

      Check that the contact surface of the fuel tank retainer is not scratched or damaged and prevent the entry of foreign objects.

    3. A0117GGE01

      Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

      Note

      Do not use any tools other than SST.

      Tech Tips


      • Hold the fuel tank vent tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position.

      • Align the ribs of the fuel pump gauge retainer with the tips of SST.

    4. A0118JDE01

      Using SST, align the marks on the fuel tank and fuel pump gauge retainer.

      SST
      09808-14020   ( 09808-01410, 09808-01420, 09808-01430 )

  4. CONNECT NO. 1 FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. A011BJEE01

      Engage the clamp and connect the No. 1 fuel evaporation tube to the fuel tank vent tube assembly.

    2. Connect the No. 1 fuel evaporation tube to the fuel tank vent tube assembly and lock them by pushing in the retainer.

      Note


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

      • Check that the No. 1 fuel evaporation tube is inserted securely.

      • After installing the retainer, check that the No. 1 fuel evaporation tube is securely connected by pulling on it.

    3. Install the No. 2 fuel tank cushion.

  5. INSTALL NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A0119WX
      Text in Illustration
      *1 Yellow mark

      Install the No. 1 charcoal canister outlet hose onto the fuel tank vent tube assembly.

      Note

      Install the No. 1 charcoal canister outlet hose with its yellow mark toward the rear of the vehicle.

    2. Clamp the No. 1 charcoal canister outlet hose.

  6. CONNECT FUEL TANK WIRE


    1. A011ASH

      Connect the fuel tank wire connector to the fuel tank vent tube assembly.

      Note

      After connecting the fuel tank wire connector, check that the fuel tank wire is inserted securely.

  7. INSTALL FUEL TANK ASSEMBLY


    1. A011ART

      Clean and degrease the bolt holes.

    2. Set the fuel tank on the engine lifter.

    3. Slowly raise the engine lifter and install the fuel tank onto the vehicle.

      Note

      Make sure that the fuel tank does not fall.

    4. A011BM1E01

      Tighten the 4 bolts in the sequence shown in the illustration, and secure the 2 fuel tank bands and the fuel tank.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  8. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY


    1. A011BTT

      Connect the fuel return tube sub-assembly.

  9. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A0119ZWE01

      Line up the pipe and connector and push them together until a "click" sound is heard.

    2. Push the checker into lock it.

      Note


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

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

      • After installing the checker, check that the fuel tank main tube is securely connected by pulling on it.

  10. CONNECT FUEL TANK FILLER PIPE SUB-ASSEMBLY


    1. A0119UEE01

      Connect the inlet tube to the fuel tank assembly and lock it by pushing in the retainer.

      Note


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

      • Check that the inlet tube is inserted securely.

      • After installing the retainer, check that the inlet tube is securely connected by pulling on it.

      Tech Tips


      • Insert the inlet tube until a "click" sound is heard.

      • The quick connector cannot be locked when the tube is not inserted securely.

    2. A011748E01

      Connect the fuel tank breather tube to the fuel tank assembly and lock it by pushing in the retainer.

      Note


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

      • Check that the breather tube is inserted securely.

      • After installing the retainer, check that the breather tube is securely connected by pulling on it.

      Tech Tips

      The quick connector cannot be locked when the tube is not inserted securely.

  11. CONNECT NO. 1 CHARCOAL CANISTER OUTLET HOSE


    1. A01178LE01
      Text in Illustration
      *1 Yellow mark

      Connect the No. 1 charcoal canister outlet hose.

      Note


      • Install the No. 1 charcoal canister outlet hose with its yellow mark toward the rear of the vehicle.

      • After connecting the fuel tank breather tube and No. 1 charcoal canister outlet hose, check that the evaporation vent tube clamp is securely connected by pulling on it.

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


    1. A0119VV

      Engage the claw and install the No. 1 fuel tank protector with the 2 clips and 4 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  13. CONNECT FUEL TANK WIRE


    1. A011BQ7

      Pull the fuel tank wire through the floor, install the grommet in the floor, and connect the fuel tank wire connector.

  14. ADD FUEL


    1. Open the fuel tank cap to add fuel.

  15. BLEED AIR FROM FUEL SYSTEM

    Click here

  16. INSPECT FOR FUEL LEAK


    1. Connect an intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Turn the tester on.

    4. Enter the following menus: Powertrain / Engine / Active Test.

    5. Perform the Active Test.

      Intelligent Tester Display Test Details Control Range Diagnostic Notes
      Test the Fuel Leak Pressurize common rail internal fuel pressure, and check for fuel leaks Stop/Start

      Perform inspection of the high pressure fuel system.

      Test is possible when the following conditions are met:


      • Warmed up engine.

      • Vehicle is stopped.

      • Battery voltage is 12 V or more.

      • PM regeneration is not operating.

      • Engine speed is less than 4000 rpm.

      Results of real-vehicle check:


      • Engine Speed: 2702 rpm


      • Fuel Pressure: 108570 kPa


      • Target Common Rail Pressure: 105500 kPa


      • Target Pump SCV Current: 1.2 A


      • MAP: 127 kPa


      • MAF: 28 g/sec.