Fuel Tank Unit Removal and Installation

Fuel Tank Unit Removal and Installation

Special Tools Required

- Fuel pump module locknut wrench 07AAA-SNAA100

Removal

1. Relieve the fuel pressure. Service and Repair

2. Remove the rear seat cushion. Rear Seat Removal/Installation

3. Remove the rear floor upper cross-member (A).






4. Remove the access panel (A) from the floor.

5. Disconnect the fuel tank unit 4P connector (B).

6. Disconnect the quick-connect fittings (C) from the fuel tank unit.






7. Using the special tool, loosen the locknut (A).






8. Remove the locknut (A) and the fuel tank unit (B).






Installation

1. Temporarily attach a new base gasket (A) to the fuel tank unit (B), then insert the fuel tank unit partially into the fuel tank.
NOTE:

- Be careful not to damage the new base gasket.

- Be careful not to bend the fuel gauge sending unit.

- Do not coat the base gasket with oil.





2. Transfer the base gasket (A) from the fuel tank unit onto the fuel tank.

3. Align the marks (B) on the fuel tank and the fuel tank unit, then insert the fuel tank unit into the fuel tank until it sits on the base gasket.
NOTE: To prevent a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.






4. Install a new locknut plate (A) and a new locknut (B).






5. Using the fuel pump module locknut wrench, tighten the new locknut (A) to the specified torque.
NOTE:

- After tightening, make sure the marks are still aligned.

- After installation, check the base gasket, visually or by hand, to make sure it is not pinched.

6. Connect the fuel tank unit 4P connector, then connect the quick-connect fitting.

7. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump will run for about 2 seconds, and fuel pressure will rise. Repeat this two or three times, then check that there is no leakage in the fuel supply system.






8. Install the access panel (A) to the floor.






9. Install the rear floor upper cross-member (A).

10. Install the rear seat cushion. Rear Seat Removal/Installation

11. Install the fuel fill cap.