Inspection Procedure

1. Proceed to the Driver's side (LH) rear wheel. Look under the vehicle in front of the rear wheel and locate the fuel filler neck on the fuel tank.





2. Check for either a green dot, green X, and/or green dot with an X strike-through on or around the fuel filler neck.

3. If there is a green marking as shown above, this vehicle does not need further inspection and can be released. If no green marking is present proceed to step 4.





4. Proceed to the right side of the vehicle.

5. Check for the date molded into the bottom of the fuel tank on the Passenger's side (RH).

6. If the month imprint is NOT pointing to the 7, this vehicle does not need further inspection and can be released.

7. If the month IS pointing to the 7 and no green mark is present as described above, proceed to step 8.

8. Raise the vehicle with a lift.

9. Proceed to the Passenger's side (RH) of the fuel tank.





10. Remove the 14 mm nut holding on the right fuel tank strap.





11. Release the fuel tank strap end from the stud mount and let strap hang.





12. Using an inspection mirror and flashlight, place the mirror at the top rear center of the fuel tank and locate the fuel tank production label.





13. On the bottom left hand side of the production label is the fuel tank production date. Locate this date.

14. If the date is 7/28/2006 with a time stamp after 08:22 or anytime on 712912006 the tank will need to be replaced. Continue to the Part Replacement section (beginning with step 17) below for the proper procedure. If vehicle needs replacement of tank, immediately order part as shown under Parts Information.

15. If the date is any other date proceed to step 16.

16. Reinstall fuel tank strap and nut. Torque nut to 44Nm (32 lb-ft). Lower vehicle and release.

REPLACEMENT PROCEDURE:





17. On the 7 passenger model flip up the 40% seat (RH) as if entering the 3rd row seat, and remove the two lower bolt covers on the 60% seat (LH).

NOTE:
On the 5 passenger model both rear seats must be removed. Steps 18 and 19 must be repeated on the passenger side rear seat.





18. Remove the two lower bolts. Tightening torque: 54Nm, 401b-ft.





19. Remove the two upper bolts and carefully remove the seat from the vehicle. Tightening torque: 54Nm, 401b-ft.





20. Gently remove both sending unit covers by prying upwards on the covers.





21. Disconnect the fuel pump connector (grey connector) on the Driver's side (LH) fuel pump assembly. Start the vehicle and allow the vehicle to run out of fuel and stall.





22. Disconnect the fuel tank pressure sensor connector on the Driver's side (LH) fuel pump assembly.





23. Disconnect the two fuel lines on top of the Driver's side (LH) fuel sending unit.

CAUTION:
Fuel line may still have residual pressure. Place rags around area to protect yourself and vehicle from contamination.

24. Disconnect the fuel sending unit connector on the Passenger's side (RH).








25. Using a brass drift, hammer the fuel pump retaining ring in a counter clockwise direction. Remove the fuel pump assembly using caution not to spill fuel. Drain the fuel into a suitable container through the removed fuel pump opening using a hand pump.





26. Loosen the hose clamp and remove the fuel filler hose from the fuel tank.

CAUTION:
Fuel hose may still contain residual fuel.





27. Disconnect the two rear EVAP lines. They can easily be located by their white connectors.





28. Disconnect the two forward EVAP lines that connect to the charcoal canister. These can also be located by their white connectors.





29. Remove the exhaust mid-pipe from the resonator to the mufflers. Take care to not misplace the exhaust gaskets. Tightening torque: 49Nm, 36Lb-ft





30. Support catalytic converter assembly with bungee cord.





31. (4WD Models Only) Mark front and rear driveshaft flanges to designate location prior to removal. Remove driveshaft.

NOTE:
Rear driveshaft flange bolts are reverse thread. Use caution during removal.

Tightening torque: 59Nm, 431b-ft.





32. Remove the center driveshaft bearing bracket.

Tightening torque: 44Nm, 321b-ft.

33. Remove the differential wire harness mounting clips from the fuel tank heat shield.

34. Support fuel tank and remove fuel tank strap nuts. Remove the fuel tank. Tightening torque: 44Nm, 321b-ft.

35. Installation of the new fuel tank is performed by the steps listed above in reverse order.

36. After complete assembly, fill the tank with 4 gallons (up to $14 equivalent) of 87 octane gasoline.

37. Using the Hi-Scan Pro or GDS, verify there are no EVAP leaks by running an EVAP Test.

38. If EVAP leaks are found refer to the shop manual for appropriate repair procedures.

39. If no EVAP leaks are found the vehicle is ready for release.