FUEL SENDER GAUGE ASSEMBLY(except Sedan) REMOVAL

PROCEDURE

REMOVE REAR SEAT ASSEMBLY (for Hatchback)

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REMOVE REAR SEAT ASSEMBLY (for Wagon)

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REMOVE REAR FLOOR SERVICE HOLE COVER
1. Disconnect the 2 connectors.
2. Remove the butyl tape and rear floor service hole cover.
3. Disconnect the connector of the fuel sender gauge assembly from the fuel tank vent tube sub-assembly.

REMOVE FUEL TANK VENT TUBE SUB-ASSEMBLY

Remove the fuel tank cap assembly, then discharge the pressure in the fuel tank assembly completely.

Disconnect the fuel tank main tube sub-assembly and fuel tank return tube sub-assembly.

Note:

Before performing this procedure, check for foreign matter on the 2 tube joint clips. Clean if necessary.

*1	Fuel Tank Return Tube Sub-assembly
*2	Fuel Tank Main Tube Sub-assembly
*3	Tube Joint Clip
*4	Fuel Tank Vent Tube Sub-assembly
*a	Fuel Tube Joint
*b	O-ring

Remove the 2 tube joint clips, then pull off the fuel tube joint from the plug of the fuel tank vent tube sub-assembly.

Note:

Remove any foreign matter on the fuel tube joint before performing this work.
Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube joint has O-rings that seal the fuel pipe.
Only disconnect the fuel tube joint by hand.
Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube joint.
If the fuel tube joint and fuel tank vent tube sub-assembly are stuck, push and pull to release them.

Pinch the tabs (A) from both sides of the fuel tank evaporation vent tube.
Pull the fuel tank evaporation vent tube in the direction indicated by the arrow in the illustration.
Disengage the 2 claws and remove the tank suction tube support.

*a	Paint Mark
	Front

Place paint marks on the fuel tank vent tube sub-assembly and vehicle body as shown in the illustration.

Note:

The fuel tank vent tube sub-assembly has 2 protrusions that engage with 2 notches on the fuel tank assembly to ensure correct alignment and to prevent the fuel tank vent tube sub-assembly from turning during installation and removal of the fuel pump gauge retainer.
If the fuel pump gauge retainer is turned with the fuel tank vent tube sub-assembly misaligned, the fuel tank vent tube sub-assembly will turn with the fuel pump gauge retainer and may be damaged.
The paint marks are used to ensure that the fuel tank vent tube sub-assembly does not turn with the fuel pump gauge retainer.

Install SST to the fuel pump gauge retainer.

Note:

Before performing these procedures, first cover the connector and tube joints of the fuel tank vent tube sub-assembly with vinyl tape and then clean any dirt and foreign matter in order to prevent contamination of the fuel system.

*1	Fuel Pump Gauge Retainer
*a	SST (Claw Set)
*b	Protrusion
*c	Notch
*d	Do not install SST (Claw Set)

Set 4 SST (claw set) to the fuel pump gauge retainer.

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Note:

Align the notch of SST (claw set) with the protrusion of the fuel pump gauge retainer.
Do not install SST (claw set) to the start of threads location of the fuel pump gauge retainer.

*1	Fuel Pump Gauge Retainer
*a	SST (Claw Set)
*b	Hook
	Push
	SST (Bolt)

Push SST (claw set) against the fuel pump gauge retainer and tighten SST (bolt).

*a	SST (Plate)
*b	SST (Claw Set)
	SST (Bolt)

Temporarily install SST (plate) to SST (claw set) with 4 SST (bolt).

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*a	Center Point of Fuel Pump Gauge Retainer
*b	SST (Plate)
	Front

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

*1	Fuel Pump Gauge Retainer
*a	SST (Plate)
*b	SST (Claw Set)
*c	SST (Bolt)
	Press

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

Install SST (handle) to SST (plate).

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*a	SST (Plate)
*b	SST (Handle)
	Loosen

Slowly loosen the fuel pump gauge retainer by approximately 90°.

Note:

Do not spin SST too fast or use an impact wrench as this may result in damage to components.

While one person loosens the fuel pump gauge retainer, have another person press down the rising fuel tank vent tube sub-assembly, securely insert the protrusion of the fuel tank vent tube sub-assembly into the groove of the fuel tank assembly, and then remove the fuel pump gauge retainer while making sure that the fuel tank vent tube sub-assembly is properly aligned.

*a	SST (Plate)	*b	SST (Handle)
*c	One Person in Charge of Loosening	*d	One Person in Charge of Pressing Down
*e	Paint Mark	-	-

Note:

The fuel tank vent tube sub-assembly is pressed against the underside of the fuel tank assembly by a spring, and the constant upward pressure applied by this spring causes the fuel tank vent tube sub-assembly to rise up.
If the fuel pump gauge retainer is turned while the fuel tank vent tube sub-assembly and fuel tank assembly are not correctly aligned, the fuel tank vent tube sub-assembly will move with the fuel pump gauge retainer, and the fuel tank vent tube sub-assembly and fuel tank assembly may both be damaged.
Do not turn the fuel pump gauge retainer if the paint marks become misaligned.

Remove the fuel tank vent tube sub-assembly from the fuel tank assembly.

Note:
Be careful not to bend the arm of the fuel sender gauge assembly.

*1	Fuel Suction Tube Set Gasket

Remove the fuel suction tube set gasket from the fuel tank assembly.

*a	Copy of Fully Tightened Mark
*b	Copy of Start of Threads Mark
*c	Fully Tightened Mark on Fuel Tank Assembly
*d	Start of Threads Mark on Fuel Tank Assembly
	Front

Copy the start of threads mark and fully tightened mark from the fuel tank assembly to the vehicle body in order to record their locations.

REMOVE FUEL SENDER GAUGE ASSEMBLY

	Push
	Pull up

Disconnect the fuel sender gauge assembly connector.

Disconnect the harness clamp.

Note:
Do not damage the wire harness.
Push the claw (A) of the fuel sender gauge assembly, and then pull up the fuel sender gauge assembly to remove it.