FUEL SENDER GAUGE ASSEMBLY INSTALLATION


  1. INSTALL FUEL SENDER GAUGE ASSEMBLY


    1. A01INLV

      Install the fuel sender gauge assembly by sliding it downward.

    2. Attach the wire harness clamp.

    3. Connect the fuel sender gauge assembly connector.

  2. INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY


    1. A01IUCYE03
      Text in Illustration
      *1 Gasket

      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. A01ITD4E02
      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. A01IQ1UE01
      Text in Illustration
      *a Center Point of Fuel Pump Gauge Retainer

      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.

    2. A01INP0E01
      Text in Illustration
      *a Start Mark (Fuel Tank Assembly Side)
      *b Start Mark (Fuel Pump Gauge Retainer Side)
      A01ISM9 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. A01IPURE01
      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.

      SST
      09808-14030   ( 09808-01010, 09808-01020, 09808-01030, 09808-01040, 09808-01050 )

      Note

      Install SST (claw) to the correct location.

    4. A01ISAFE01
      Text in Illustration
      *a SST (Plate)
      *b SST (Claw)
      *c SST (Bolt)
      A01ISM9 Press

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

    5. A01IRSGE01
      Text in Illustration
      *a SST (Plate)
      *b Start Mark (Fuel Pump Gauge Retainer Side)
      *c Worker A
      *d Worker B
      *e Approximately 180°
      A01ISM9 Press Down
      A01ISER Slowly Rotate
      A01IQPE 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.

      A01IOJDE01
      Text in Illustration
      *1 Fuel Pump Gauge Retainer *2 Fuel Tank Assembly
      *a SST (Plate) *b Press Quickly and Firmly
      *c Fuel Pump Gauge Retainer Rise Up Area *d 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. A01ITWLE01
      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
      A01ISM9 Press Down
      A01ISER Slowly Rotate
      A01IQPE 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. A01IO5LE01
        Text in Illustration
        *1 Fuel Pump Gauge Retainer
        *2 Fuel Tank Assembly
        *a Measurement Location
        *b Vernier Caliper
        A01ISM9 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).

      SST
      09808-14030   ( 09808-01010, 09808-01020, 09808-01030, 09808-01040, 09808-01050 )
    10. A01IO14E01
      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
      A01ISM9 Hold Down
      A01ISER Slowly Rotate
      A01IQPE 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 tank suction tube support.

  5. CONNECT FUEL TANK RETURN TUBE SUB-ASSEMBLY


    1. A01IU26E02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tank Return Tube Sub-assembly
      *3 O-Ring
      *4 Tube Joint Clip
      *5 Collar
      *a CORRECT
      *b INCORRECT

      Push the fuel tank return tube sub-assembly 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.

  6. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY


    1. A01IUPPE02
      Text in Illustration
      *1 Tube Joint Clip
      *2 Fuel Tank Main Tube Sub-assembly
      *3 O-Ring
      *4 Tube Joint Clip
      *5 Collar
      *a CORRECT
      *b INCORRECT

      Push the fuel tank main tube sub-assembly 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.

  7. INSTALL REAR FLOOR SERVICE HOLE COVER


    1. A01IUNL

      Connect the 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


    1. A01IQ0Q

      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. A01IRMJE03

      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.

      A01IRYOE04

      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.

  9. 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.


    1. Perform Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Enter the following menus: Powertrain / Engine and ECT/ Active Test.

      6. 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: 1.4 A

        • MAP: 176 kPa

        • MAF: 39 g/sec.

  10. INSTALL REAR CENTER SEAT ASSEMBLY (w/ Rear No. 1 Seat)

    Click here

  11. INSTALL REAR NO. 1 SEAT ASSEMBLY (w/ Rear No. 1 Seat)

    Click here