Fuel sender gauge ASSY (FA20)
Components Inspection Removal / installation
FUEL
FUEL SENDER GAUGE ASSY (FA20)
EXPLODED VIEW
REMOVAL
1. Fuel spill prevention procedure (Refer to 
)
)2. Draining of fuel (Refer to )
)3. Disconnection of the battery ground terminal (Refer to )
)4. Removal of separate type rear seat cushion ASSY RH (Refer to )
)5. Removal of separate type rear seat cushion ASSY LH (Refer to )
)6. Removal of rear floor service hole cover NO.2 (Refer to )
)7. Removal of fuel pump ASSY (Refer to )
)
8. Removal of fuel sender gauge ASSY
(1) Disconnect the fuel sender gauge connector and remove the harness from the clamp.
(2) Push up the claw to remove the fuel sender gauge ASSY.
CAUTION:
Do not bend the arm of fuel sender gauge ASSY.
9. Rear floor service hole cover removal
(1) Push in the grommet to remove the grommet from the rear floor service hole cover.
(2) Remove the butyl tape and remove the rear floor service hole cover.
(3) Disconnect the fuel sub sender gauge connector.
10. Fuel sub sender gauge ASSY removal
(1) Use the SST to loosen the ring nut.
SST
42099CA000
CAUTION:
·If the fuel gauge indicates that two thirds or more of the fuel is remaining, be sure to drain the fuel before starting the work to avoid the fuel to spill.
·Do not use any tools other than the SST.
·Do not turn the fuel sub sender gauge ASSY in the fuel tank ASSY to prevent the arm of fuel sender gauge ASSY NO.2 from bending.
·Do not use any tools other than the SST.
·Do not turn the fuel sub sender gauge ASSY in the fuel tank ASSY to prevent the arm of fuel sender gauge ASSY NO.2 from bending.
NOTE:
Insert the cutout portion of SST into the rib of ring nut to fix the SST securely.
(2) Take out the fuel sub sender gauge ASSY from the fuel tank and remove the filter and fuel delivery tube as a unit from the fuel sub sender gauge ASSY.
CAUTION:
·Do not bend the arm of fuel sender gauge ASSY NO.2.
·Be careful not to spill the fuel outside the fuel tank or in the vehicle.
·Be careful not to spill the fuel outside the fuel tank or in the vehicle.
11. Fuel sender gauge ASSY NO.2 removal
(1) Disconnect the connector from the fuel sender gauge ASSY NO.2 and remove the harness from the clamp.
(2) Push the claw and remove the fuel sender gauge ASSY NO.2 by sliding it in the direction as shown in the figure.
CAUTION:
Do not bend the arm of fuel sender gauge ASSY NO.2.
INSTALLATION
1. Fuel sender gauge ASSY NO.2 installation
(1) Engage the claw and install the fuel sender gauge ASSY NO.2 to the fuel sub delivery tube.
(2) Connect the fuel sender gauge ASSY NO.2 connector and install the harness to the clamp.
2. Fuel sub sender gauge ASSY installation
(1) Install a new gasket to the fuel tank.
CAUTION:
·Do not bend the arm of fuel sender gauge ASSY NO.2.
·Improper installation such as warpage, slip, etc. results in fuel leakage. Make sure that there is no warpage, slip, etc. in the entire circumference when installing the gasket to the fuel tank.
·Improper installation such as warpage, slip, etc. results in fuel leakage. Make sure that there is no warpage, slip, etc. in the entire circumference when installing the gasket to the fuel tank.
(2) Apply gasoline to the gasket.
Captions in illustration
| *1 |
Gasket |
| *a |
Areas of gasoline application |
CAUTION:
·When applying gasoline to the gasket, apply it to the area as shown in the figure.
·Be careful that no gasoline comes into contact with the threaded portion of fuel tank.
·Make sure that there is no fuel, foreign matter, etc. on the sealing portion.
·Be careful that no gasoline comes into contact with the threaded portion of fuel tank.
·Make sure that there is no fuel, foreign matter, etc. on the sealing portion.
(3) Install the fuel sub delivery tube together with the filter to the fuel sub sender gauge ASSY.
(4) Set the fuel sub sender gauge ASSY in the installation position range mark of fuel tank.
Captions in illustration
| *a |
Installation position range mark |
CAUTION:
Do not bend the arm of fuel sender gauge ASSY NO.2.
(5) Install a new ring nut plate and ring nut, and then temporarily tighten the ring nut.
(6) Tighten the ring nut using the SST.
Standard value:
SST
42099CA000
Standard value:
Tightening torque=85N·m
{
867kgf·cm}
{62.7ft·lbf}
CAUTION:
·Do not use any tools other than the SST.
·Make sure that the position mark on the fuel sub sender gauge ASSY is located within the installation position range mark on the fuel tank as shown in the figure.
·After tightening to the specified torque, confirm the tightening by tightening it to the specified torque again.
·Make sure that the position mark on the fuel sub sender gauge ASSY is located within the installation position range mark on the fuel tank as shown in the figure.
·After tightening to the specified torque, confirm the tightening by tightening it to the specified torque again.
NOTE:
Insert the cutout portion of SST into the rib of ring nut to fix the SST securely.
3. Rear floor service hole cover installation
(1) Connect the connector and install the rear floor service hole cover using new butyl tape.
4. Fuel sender gauge ASSY installation
(1) Slide the fuel sender gauge downward to install it.
(2) Install the fuel sender gauge connector.
5. Fuel pump ASSY installation (Refer to )
)6. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
7. Rear floor service hole cover NO.2 installation (Refer to )
)8. Separate type rear seat cushion ASSY RH installation (Refer to )
)9. Separate type rear seat cushion ASSY LH installation (Refer to )
)UNIT INSPECTION
1. Fuel sender gauge ASSY check (fuel sender gauge main)
(1) Visual inspection
(a) Check the fuel sender gauge ASSY for damage.
(b) Check the dimensions between the float and fuel tank seating surface when the float is at F (upper limit) and E (lower limit).
Dimension
| Float position F (upper limit) - fuel tank seating surface |
121 to 129 mm {4.76 to 5.08 in} |
| Float position E (lower limit) - fuel tank seating surface |
14.7 to 22.7 mm {0.579 to 0.894 in} |
Captions in illustration
| *1 |
Float position F (upper limit) |
| *2 |
Float position E (lower limit) |
| *3 |
Fuel tank seating surface |
(2) Resistance check
WARNING:
Be careful of fire.
(a) Check that the float moves smoothly between the positions F (upper limit) and E (lower limit).
(b) Check the resistance between the connector terminals when the float is at F (upper limit) and E (lower limit). Also check that the resistance varies continuously.
Resistance
| Inspection terminals |
Inspection conditions |
Standard value |
|---|---|---|
| 1 - 2 |
Float position F (upper limit) |
6.5 to 8.5 Ω |
| Float position E (lower limit) |
168 to 172Ω |
Captions in illustration
| *1 |
Connector not connected (Fuel sender gauge ASSY) |
| *a |
F (upper limit) |
| *b |
E (lower limit) |
2. Fuel sender gauge ASSY NO.2 check (fuel sender gauge sub)
(1) Visual inspection
(a) Check the fuel sender gauge ASSY NO.2 for damage.
(b) Check the dimensions between the float and fuel tank seating surface when the float is at F (upper limit) and E (lower limit).
Dimension
| Float position F (upper limit) - fuel tank seating surface |
150.3 to 158.3 mm {5.92 to 6.23 in} |
| Float position E (lower limit) - fuel tank seating surface |
0.7 to 8.7 mm {0.03 to 0.34 in} |
Captions in illustration
| *1 |
Float position F (upper limit) |
| *2 |
Float position E (lower limit) |
| *3 |
Fuel tank seating surface |
(2) Resistance check
WARNING:
Be careful of fire.
(a) Check that the float moves smoothly between the positions F (upper limit) and E (lower limit).
(b) Check the resistance between the connector terminals when the float is at F (upper limit) and E (lower limit). Also check that the resistance varies continuously.
Resistance
| Inspection terminals |
Inspection conditions |
Standard value |
|---|---|---|
| 1 - 2 |
Float position F (upper limit) |
5.5 to 9.5 Ω |
| Float position E (lower limit) |
236 to 244 Ω |
Captions in illustration
| *1 |
Connector not connected (Fuel sender gauge ASSY NO.2) |
| *a |
F (upper limit) |
| *b |
E (lower limit) |