Toyota Yaris: Fuel Sender Gauge Assembly / Installation

Toyota Yaris XP210 (2020-2024) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (fuel) / Fuel Sender Gauge Assembly / Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 2 FUEL SENDER GAUGE ASSEMBLY

(a) Attach the claw and install the No. 2 fuel sender gauge assembly.

NOTICE:

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

(b) Attach the 2 clamps and connect the wire harness to the fuel tank vent tube assembly.

NOTICE:

Do not damage the wire harness.

(c) Connect the connector to the fuel tank vent tube assembly.

2. INSTALL FUEL TANK VENT TUBE ASSEMBLY

(a) Install a new 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.

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*1

Fuel Return Vent Tube Sub-assembly

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.

3. INSTALL FUEL PUMP GAUGE RETAINER

HINT:

Perform the same procedure as for the fuel suction tube with pump and gauge assembly.

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4. INSTALL NO. 1 FUEL TUBE CLAMP

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5. INSTALL REAR FLOOR SERVICE HOLE COVER (for RH Side)

(a) Remove any remaining butyl tape from the rear floor service hole cover and body.

(b) Connect the connector to the fuel tank vent tube assembly.

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

NOTICE:

Securely install the rear floor service hole cover.

6. INSTALL FUEL SENDER GAUGE ASSEMBLY

(a) Attach the claw and install the fuel sender gauge assembly.

NOTICE:

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

(b) Connect the 2 connectors to the fuel suction plate sub-assembly.

(c) Attach the 3 clamps and connect the wire harness.

NOTICE:

Do not damage the wire harness.

7. INSTALL FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

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    Inspection

    INSPECTION PROCEDURE 1. INSPECT FUEL SENDER GAUGE ASSEMBLY CAUTION: Perform the inspection in a well-ventilated area. Do not perform the inspection near an open flame...

    Fuel System

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    Categories

    Break-In Period

    No special break-in is necessary, but a few precautions in the first 600 miles (1,000 km) may add to the performance, economy, and life of the vehicle.

    Do not race the engine. Do not maintain one constant speed, either slow or fast, for a long period of time. Do not drive constantly at full-throttle or high engine rpm for extended periods of time. Avoid unnecessary hard stops. Avoid full-throttle starts.

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