FUEL SENDER GAUGE ASSEMBLY(except Sedan) INSTALLATION

PROCEDURE

INSTALL FUEL SENDER GAUGE ASSEMBLY
1. Install the fuel sender gauge assembly by sliding it downward.
2. Connect the harness clamp.
  
  Note:
  Do not damage the wire harness.
3. Connect the connector of the fuel sender gauge assembly.

INSTALL FUEL TANK VENT TUBE SUB-ASSEMBLY

*1	Fuel Suction Tube Set Gasket

Install a new fuel suction tube set gasket onto the fuel tank assembly.

Set the fuel tank vent tube sub-assembly to the fuel tank assembly.

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

*a	Notch
*b	Protrusion

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

Install SST to the fuel pump gauge retainer.

*1	Fuel Pump Gauge Retainer
*a	SST (Claw)
*b	Narrow
*c	Wide
*d	Correct
*e	Incorrect

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

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Note:

Install SST (claw) to the correct location.
Do not install SST (claw) to a location where the pitch between ribs of the fuel pump gauge retainer is narrow.

*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.

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

*a	Front
*b	Press
*c	Start of Threads of the Fuel Pump Gauge Retainer
*d	Copy of Start of Threads Mark
*e	Align

While pressing down on the fuel tank vent tube sub-assembly, have another person align the start of the threads of the fuel pump gauge retainer with the start of the threads mark that was copied onto the vehicle body.

*1	Fuel Pump Gauge Retainer
*2	Fuel Tank Assembly
*a	Front
*b	Tighten approximately 90°
*c	Fuel Pump Gauge Retainer rises up
*d	Press quickly and firmly
*e	Cross Section

While pressing down on the fuel tank vent tube sub-assembly, have another person firmly press the fuel pump gauge retainer against the threads of the fuel tank assembly, and tighten the fuel pump gauge retainer by approximately 90°.

Quickly and firmly press down on the part of the fuel pump gauge retainer closest to the rear of the vehicle to keep it from rising up.
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 be sure SST is horizontal when turning.
- 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.
Tip:
- 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 tactile sensation of parts contacting and pressing together when the fuel pump gauge retainer is fully pressed down, and at this point the fuel tank vent tube sub-assembly will stop rising up.

*a	One Person in Charge of Tightening
*b	One Person in Charge of Holding
*c	Front
*d	Tighten approximately 180°

While pressing down on the fuel tank vent tube sub-assembly, have another person slowly tighten the fuel pump gauge retainer by approximately 180°.

*a	Front
*b	Measurement Position
*c	Vernier Caliper
*d	A-A Cross Section

Check the tightening status of the fuel pump gauge retainer.

Using a vernier caliper, measure the distance from the fuel tank assembly to the upper surface of the fuel pump gauge retainer at 3 positions as shown in the illustration.

Standard

Difference between the 3 measured values is 3 mm (0.118 in.) or less.

Note:
If the difference between measurements is approximately 6 mm (0.236 in.), the threads are cross-threaded by 1 row (6 mm (0.236 in.)), so remove and reinstall the fuel pump gauge retainer.

Install SST (handle).

*a	One Person in Charge of Tightening
*b	One Person in Charge of Holding
*c	Start of Threads of the Fuel Pump Gauge Retainer
*d	Copy of Fully Tightened Mark
*e	Front

While pressing down on the fuel tank vent tube sub-assembly, have another person use the SST (handle) to slowly tighten the fuel pump gauge retainer by 90°(after tightening, there will be remaining until the fully tightened mark).

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*a	Hold Down
*b	Pull

While holding down on the center of SST (handle) to prevent SST from separating from the fuel pump gauge retainer, pull SST (handle) with another person pulling the opposite end of SST (handle), and slowly tighten the fuel pump gauge retainer until it reaches the fully tightened mark.

Engage the 2 claws to install the tank suction tube support.
Install the fuel tank evaporation vent tube.

Note:
Securely install the fuel tank evaporation vent tube by pushing it until it makes a "click" sound.

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

Push the 2 fuel tube joints onto the plugs of the fuel tank vent tube sub-assembly, then install the 2 tube joint clips.

*1	Fuel Tank Return Tube Sub-assembly	*2	Fuel Tank Main Tube Sub-assembly
*3	Tube Joint Clip	-	-
*a	Fuel Tube Joint	*b	O-ring
*c	Collar	*d	Correct
*e	Incorrect	-	-

Note:

Check that there are no scratches or foreign matter on the connecting parts.
Check that the fuel tube joints are inserted securely.
Check that the tube joint clips are on the collars of the fuel tube joints.
After installing the tube joint clips, check that the fuel tube joints have not been pulled off.
Be careful not to damage any tube joint clips. If a tube joint clip is damaged, replace it.

Connect the fuel sender gauge assembly connector.

CHECK AIRTIGHTNESS

*a	Air

After installing the fuel tank vent tube sub-assembly, check for fuel leaks by first applying soapy water to the area where the fuel tank vent tube sub-assembly and fuel pump gauge retainer contact, and then blow forcefully into the fuel inlet area through a flexible pouring spout or similar tube.

Blow forcefully until the reverse flow prevention valve inside the fuel inlet activates.

CAUTION:
Be careful not to inhale any fuel vapor.

Tip:
There should be a faintly audible sound when the reverse flow prevention valve operates.

*a	Air Bubbles

If improper installation of the fuel tank vent tube sub-assembly, etc. has resulted in a condition where fuel will leak, air will leak out as shown in the illustration.

Note:

If air leaks out, recheck the installation condition, and replace the used fuel pump gauge retainer and gasket with new ones. Also, make sure to fully wipe away the soapy water. (Any remaining soapy water can cause the gasket to slip and result in an improper assembly.)

BLEED AIR FROM FUEL SYSTEM

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INSPECT FOR FUEL LEAK

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INSTALL REAR FLOOR SERVICE HOLE COVER
1. Install the rear floor service hole cover with new butyl tape.
  
  Note:
  Be careful that the rear floor service hole cover does not cover the protrusions of the floor panel when installing.
INSTALL REAR SEAT ASSEMBLY

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