Fuel Tank Unit Removal/Installation
Fuel Tank Unit Removal and Installation
Removal
1. Fuel Fill Cap
1. Remove the fuel fill cap to relieve the pressure in the fuel tank.
2. HDS DLC - Connection
1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.
2. Turn the ignition switch to ON (II).
3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.
3. Fuel Pump Off
1. From the INSPECTION MENU of the HDS, select Fuel Pump OFF, then start the engine, and let it idle until it stalls.
NOTE:
* Do not allow the engine to idle above 1,000 rpm or the PCM will continue to operate the fuel pump.
* Pending or Confirmed DTC may be set during this procedure. Check for DTCs, and clear them as needed.
2. Turn the ignition switch to LOCK (0).
4. Battery Terminal - Disconnection
1. Make sure the ignition switch is in LOCK (0).
2. Disconnect and isolate the negative cable (A) from the battery.
NOTE: Always disconnect the negative side first.
3. Disconnect the positive cable (B) from the battery.
5. Fuel Gauge Sending Unit Access Panel
1. Remove the access panel (A) from the floor.
2. Disconnect the connector (B).
6. Fuel Pressure - Relieving (Fuel Tank Unit)
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Check the fuel quick-connect fitting for dirt, and clean it if needed.
2. Place a rag or shop towel (A) over the quick-connect fitting.
3. Disconnect the quick-connect fitting: Hold the connector (A) with one hand, and squeeze the retainer tabs (B) with the other hand to release them from the locking tabs (C). Pull the connector off.
NOTE:
* Be careful not to damage the line (D) or other parts.
* Do not use tools.
* If the connector does not move, keep the retainer tabs pressed down, and alternately pull and push the connector until it comes off easily.
* Do not remove the retainer from the line; once removed, the retainer must be replaced with a new one.
7. Fuel Tank Unit
1. Using the special tool, loosen the locknut (A).
2. Remove the locknut (A).
3. Remove the fuel tank unit (B).
Installation
1. Fuel Tank Unit
1. Insert the fuel tank unit (A) partially into the fuel tank with a new O-ring (B).
2. Align the marks (A) on the fuel tank and fuel tank unit, then insert the fuel tank unit into the fuel tank until.
NOTE: To avoid a fuel leak, check the base gasket, visually or by hand, to make sure it is not pinched.
3. Tighten a new locknut (A) by hand holding the fuel tank unit vertically.
NOTE: Before tightening, align the mark (B) on the locknut to the start of the thread (C).
4. Using the special tool, tighten the locknut 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.
2. Fuel Line/Quick-Connect Fitting - Connection (Fuel Tank Unit)
NOTE: Before you work on the fuel lines and fittings, read the Fuel Line/Quick-Connect Fitting Precautions. Service Precautions
1. Connect the quick-connect fitting (A) to the fuel tank unit (B).
3. Fuel Gauge Sending Unit Access Panel
1. Connect the connector (A).
2. Install the access panel (B) to the floor.
4. Battery Terminal - Reconnection
NOTE: If the battery performance is abnormal, test the battery.
1. Clean the battery terminals.
2. Connect the positive cable (A) to the battery.
NOTE: Always connect the positive side first.
3. Connect the negative cable (B) to the battery.
4. Apply multipurpose grease to the terminals to prevent corrosion.
5. Fuel Fill Cap
1. Install the fuel fill cap.
6. Fuel Line Leak Check
1. Turn the ignition switch to ON (II) (but do not operate the starter motor). The fuel pump runs for about 2 seconds, and fuel pressure rises. Repeat this two or three times, then make sure there are no fuel leaks.