RM38N0EC _51 Engine / Hybrid System _111793 M20C-FKS, M20D-FKS FUEL _0504185 FUEL SENDER GAUGE ASSEMBLY A

M20C-FKS, M20D-FKS FUEL  FUEL SENDER GAUGE ASSEMBLY  INSTALLATION  


PROCEDURE

Hide 83320B 1.INSTALL NO. 2 FUEL SENDER GAUGE ASSEMBLY

a.

Engage the claw to install the No. 2 fuel sender gauge assembly to the fuel tank vent tube assembly.

NOTICE:

Be careful not to bend the arm of the No. 2 fuel sender gauge assembly.



b.

Engage the 2 clamps to connect the wire harness to the fuel tank vent tube assembly.

NOTICE:
·

Do not damage the wire harness.

·

When engaging each wire harness to the clamp, engage one wire at a time.




c.

Connect the No. 2 fuel sender gauge assembly connector.


Hide 77010 2.INSTALL FUEL TANK VENT TUBE ASSEMBLY

a.

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


b.

Connect the fuel return vent tube sub-assembly and set the fuel tank vent tube assembly to the fuel tank assembly.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION

NOTICE:
A499868C01
1.823,1.885 1.823,1.625 true 1.76,1.896 1.969,2.104 0.208,0.208 10 false *a
*1 Fuel Return Vent Tube Sub-assembly
V100135

Front of the Vehicle


·

Make sure to correctly assemble the fuel return vent tube sub-assembly as shown in the illustration. If assembled incorrectly, the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) may catch on the fuel return vent tube resulting in incorrect operation of the fuel sender gauge assembly (No. 2 fuel sender gauge assembly) and an incorrect value being displayed on the fuel gauge.

·

When connecting the fuel tube connector, do not excessively pull on the fuel return vent tube sub-assembly.

·

Be careful not to bend the arm of the No. 2 fuel sender gauge assembly.




c.
A476882
0.479,0.698 0.781,0.698 true 0.24,0.615 0.469,0.833 0.229,0.219 10 true *a
*a Protrusion
V100135

Notch


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


Hide 77144 3.INSTALL FUEL PUMP GAUGE RETAINER

a.

Install the fuel pump gauge retainer.

i.

While pressing down on the fuel tank vent tube assembly, temporarily install the fuel pump gauge retainer.


ii.
A476872C01
0.823,0.708 1,0.708 1,0.708 1.385,0.927 true 2.375,0.406 2.583,0.156 2.583,0.156 2.771,0.156 true 2.26,1.417 2.469,1.771 2.469,1.771 2.656,1.771 true 0.781,1.354 1.302,1.354 true 0.885,2.979 1.958,2.979 true 2.49,0.781 3.01,0.781 true 2.021,2.875 2.24,3.094 0.219,0.219 10 true *a 2.708,1.698 2.906,1.896 0.198,0.198 10 true *b 0.573,1.25 0.76,1.448 0.188,0.198 10 true *c 0.646,0.625 0.823,0.813 0.177,0.188 10 true *d 2.792,0.073 2.99,0.25 0.198,0.177 10 true *d 3.052,0.698 3.24,0.896 0.188,0.198 10 true *c
*a Insertion Point
*b SST (Plate)
*c SST (Claw)
*d SST (Bolt)


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

SST
09808-01071  
09808-14031  (09808-01030, 09808-01090)

HINT:

Securely insert the ends of SST (claw) into the insertion points in the fuel pump gauge retainer.



iii.

While firmly pressing SST (claw) into the insertion points in the fuel pump gauge retainer, tighten SST (bolt).


iv.
A476883
0.969,3.625 1.219,3.625 true 0.344,3.646 0.542,3.646 true 1.688,0.573 1.479,0.219 1.479,0.219 1.333,0.219 true 2.146,1.229 2.469,1.354 2.469,1.354 2.646,1.354 true 0.75,1.896 0.865,1.896 0.865,1.896 1.156,1.771 true 1.083,1.417 1.229,1.417 1.229,1.417 1.365,1.573 true 1.76,1.073 2.188,0.896 2.188,0.896 2.354,0.896 true 1.271,3.542 1.438,3.719 0.167,0.177 10 true *a 0.135,3.563 0.313,3.75 0.177,0.188 10 true *b 1.104,0.125 1.292,0.302 0.188,0.177 10 true *c 0.594,1.813 0.792,2.01 0.198,0.198 10 true *d 0.927,1.333 1.083,1.51 0.156,0.177 10 true *e 2.396,0.792 2.542,0.969 0.146,0.177 10 true *f 2.677,1.25 2.927,1.458 0.25,0.208 10 true *e
*a Triangle Mark (Fuel Pump Gauge Retainer)
*b Triangle Mark (Fuel Tank Assembly)
*c SST (Handle)
*d SST (Plate)
*e SST (Bolt)
*f Extension Bar


Install SST (handle) and an extension bar to SST (plate).

SST
09808-14031  (09808-01010)


v.

Using SST, rotate the fuel pump gauge retainer so that the triangle mark on the fuel pump gauge retainer is aligned with the triangle mark on the fuel tank assembly to install the fuel tank vent tube assembly to the fuel tank assembly.

NOTICE:
·

Do not use any tools other than specified as this may result in damage to the fuel pump gauge retainer or fuel tank assembly.

·

Do not press down on SST excessively as this may make the fuel pump gauge retainer hard to rotate, and may damage components.

·

Make sure to rotate SST (handle) horizontally. If it is rotated at an angle, SST may come off.

·

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

·

If SST comes off of the fuel pump gauge retainer, loosen SST (bolt) and reinstall SST.

·

Make sure that the fuel suction tube set gasket does not come off.





b.

Engage the claw to install the No. 1 fuel tube clamp.


Hide 58325E 4.INSTALL REAR FLOOR SERVICE HOLE COVER (for RH Side)

a.

Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.


b.

Clean the installation surfaces of the rear floor service hole cover and vehicle body.


c.

Connect the fuel tank vent tube assembly connector.


d.
A476884C01
0.583,1.115 0.969,1.115 true 0.406,1.021 0.583,1.188 0.177,0.167 10 true *a
*a Butyl Tape Adhesion Area


Install the rear floor service hole cover with new butyl tape.

NOTICE:

Securely install the rear floor service hole cover.



Hide 83320 5.INSTALL FUEL SENDER GAUGE ASSEMBLY

a.

Engage the claw to install the fuel sender gauge assembly to the fuel sub-tank sub-assembly.

NOTICE:

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



b.

Engage the 2 clamps to connect the wire harness to the fuel suction tube with pump and gauge assembly.

NOTICE:
·

Do not damage the wire harness.

·

When engaging each wire harness to the clamp, engage one wire at a time.




c.

Engage the 2 clamps to connect the wire harness to the fuel suction tube with pump and gauge assembly.

NOTICE:
·

Do not damage the wire harness.

·

When engaging each wire harness to the clamp, engage one wire at a time.




d.

Connect the fuel pump harness connector and fuel sender gauge assembly connector.