Procedure - A, B and C
PROCEDURE A (Fuel Tank Removal, Inspection, and Installation)WARNING:
^ Make sure the Fuel Tank Level is 1/8 or less. If needed, use a suitable device to pump fuel out of the Fuel Tank.
^ Before performing any of the Service Procedures below, be certain there are no ignition sources (i.e., open flames, sparks, etc.) in or around the vehicle/work area.
^ Make sure the appropriate rated fire extinguisher is available for immediate use.
^ Use suitable protective gloves, safety glasses, or face shield.
To perform this procedure, you'll need:
^ Essential Vacuum Gauge Kit J-47329 (sent to each dealer)
^ Essential Vacuum Pump J-42909 (or equivalent)
Preliminary Steps
1. Release the fuel pressure as follows:
a. Connect CONSULT-II to the vehicle.
b. Turn the Ignition Switch to the "ON" position.
c. Perform "FUEL PRESSURE RELEASE" in the "WORK SUPPORT" mode.
d. Start the engine.
e. After the engine stalls, crank it two or three times to release all fuel pressure.
f. Turn the Ignition Switch "OFF".
2. Turn the Ignition Switch "ON" and write down all radio station presets.
3. Write down the reading on the Fuel Gauge (1/2 full, 1/4 full, etc.).
4. Turn the Ignition Switch "OFF" and disconnect the negative battery cable.
5. Remove the Fuel Filler Cap to release any pressure in the Fuel Tank.
Parts Removal
1. Remove the Rear Lower Seat Cushion.
^ Pull UP at two locations to release the Metal Ring from the Plastic Retainer (see Figure 2).
2. Remove the Inspection Hole Cover as follows:
a. Turn each Attachment Clip 90° (see Figure 3a).
b. Then, lift the Cover UP and reach under and disconnect the Fuel Level Sensor/Pump Assembly Connector (see Figure 3b).
CAUTION:
Be careful of the sharp edges around the Inspection Hole (see Figure 3b).
3. Disconnect the Fuel Feed Hose Quick Connector from the Fuel Level Sensor/Pump Assembly.
^ First, press IN on the two side Lock Tabs (see Figure 4).
^ Then, pull BACK on the Quick Connector (see Figure 4).
CAUTION:
^ The Quick Connector can be removed when the two side Lock Tabs are completely depressed.
^ Do NOT twist the Fuel Feed Hose more than necessary.
^ Do NOT use any tools to remove the Quick Connector.
4. Raise the vehicle on a hoist.
5. Remove the Center Exhaust Tube as follows:
For Vehicles With QG18DE Engine
a. Remove two Nuts that secure the Center Exhaust Tube to the Front Exhaust Tube (see Figure 5a).
b. Remove two Nuts that secure the Center Exhaust Tube to the rear Muffler (see Figure 5b).
For Vehicles With QR25DE Engine
a. Remove two Nuts that secure the Center Exhaust Tube to the Front Exhaust Tube (see Figure 6).
b. Remove two Nuts and remove the Center Exhaust Tube Support Bracket (see Figure 6).
C. Remove two Nuts and remove the Metal Cross Bracket (see Figure 7a).
d. Remove two Bolts that secure the Center Exhaust Tube to the rear Muffler (see Figure 7b).
6. Disconnect the following Fuel Tank Hoses from the vehicle (leave them connected to the Tank). See Figure 8.
^ EVAP Hoses (qty 2)
^ Fuel Filler Hose (qty 1)
^ Vent Hose (qty 1)
NOTE:
Mark the hoses with a permanent marker/duct tape for proper re-installation.
7. If the Fuel Tank level is over 1/8 full, use a suitable fuel removal device to pump fuel out of the Fuel Tank Filler Hose (see Figure 9).
^ Pump fuel out until the Fuel Tank level is 1/8 full or less.
8. Place a suitable Jack under the Fuel Tank and then remove the two Bolts that secure the Fuel Tank Support Straps (see Figure 10).
9. Lower the Fuel Tank 3 inches and remove the Fuel Tank Protector as follows:
For Vehicles With QG18DE Engine
a. Remove two Nuts and two Plastic Clips that hold the Fuel Tank Protector (see Figure 11).
^ To remove the Plastic Clips, press IN on the Lock Tabs (see Figure 11).
b. Remove the Protector.
For Vehicles With QR25DE Engine
a. Remove four Nuts and two Plastic Clips that hold the Fuel Tank Protector (see Figure 12).
^ To remove the Plastic Clips, press IN on the Lock Tabs (see Figure 12).
b. Remove the Protector.
10. Remove the Fuel Tank from the vehicle and drain any remaining fuel into a suitable container. Then, place the tank on a sturdy, clean work surface.
11. Mark the outer EVAP Hose and outer Vent Hose with a permanent marker for proper re-installation, then remove these hoses from the Fuel Tank (see Figure 13).
Fuel Tank Test
12. Turn the Fuel Tank upside down (bottom side up) and then "prop up" the filler-outlet side of the Tank with a piece of "2X4" wood as shown in Figure 14.
^ The Tank must be at a 20° angle (approximately) to perform the Fuel Tank test. Using the "2X4 wood will give you an approximate 20° angle.
^ Make sure any residual fuel (inside the tank) runs off to the lowest side of the tank and does not contact any of the internal tank components.
CAUTION:
Do NOT damage the Fuel Level Sensor/pump Assembly.
13. Get the Vacuum Gauge and Hose Adapter Plug from the Vacuum Gauge Kit J-47329 (see Figure 15).
14. Confirm the Vacuum Gauge does NOT have any leaks as follows:
a. Connect the large and small Tube (from the LH side of the gauge) to the Hose Adapter Plug (see Figure 16).
b. Connect the remaining small Tube to a "known good" Vacuum Pump (see Figure 16).
c. Apply vacuum and make sure there are no leaks (gauge does NOT lose vacuum).
IMPORTANT:
When applying vacuum:
^ Squeeze the Vacuum Pump handle slowly as the Vacuum Gauge is very sensitive.
^ Do NOT exceed the limits of the Vacuum Gauge.
15. Connect the Vacuum Gauge to the Fuel Tank as shown in Figure 17. Then apply - 50 inH2O of vacuum to the Fuel Tank and monitor the vacuum for 5 minutes.
^ The remaining open hoses on the tank do NOT need to be plugged to perform this procedure.
^ During the 5-minute vacuum test, occasionally tap on the bottom, center area of the Fuel Tank.
a. If, after 5 minutes, the vacuum is anywhere between - 50 and - 2.0 inH2O:
> The Fuel Tank is OK.
> Go to "Fuel Tank Installation".
b. If, after 5 minutes, the vacuum is below - 2.0 inH2O:
> The Fuel Tank is NG.
> Install a new Fuel Tank (see Parts Information for tank P/N).
> Go to "Fuel Tank Installation".
Fuel Tank Installation
1. Install the Fuel Tank in the reverse order of removal, making sure:
^ All Fuel Tank Hoses are properly installed and securely tightened.
^ The Fuel Level Sensor/Pump Assembly Connector is securely reconnected.
^ The Fuel Feed Hose Quick Connector is securely snapped in place (the connector will "click when it's locked into position). Pull on the Quick Connector to make sure it's fully locked into position.
2. Check the Fuel Feed Hose Quick Connector for leaks as follows:
a. First, apply fuel pressure to the fuel system by turning the Ignition Switch to the "ON" position (without starting the engine).
b. Then, check for fuel leaks at the Quick Connector.
c. Finally, start the engine and increase the idle speed. Then confirm there are no fuel leaks at the Quick Connector.
PROCEDURE B (EVAP Canister Removal and Installation)
WARNING:
^ Before performing any of the Service Procedures below, be certain there are no ignition sources (i.e., open flames, sparks, etc.) in or around the vehicle/work area.
^ Make sure the appropriate rated fire extinguisher is available for immediate use.
^ Use suitable protective gloves, safety glasses, or face shield.
Parts Removal
1. Remove two Plastic Clips and one Bolt and remove the EVAP Canister Protector (see Figure 18).
2. Disconnect the following from the EVAP Canister (refer to Figure 19):
^ EVAP Vent Control Valve Hose (disconnect from vehicle metal pipe)
^ EVAP Purge Hose
^ EVAP/ORVR Hose (press IN on both Tabs to release)
^ EVAP Vent Control Valve Connector
^ EVAP Pressure Sensor Connector
3. Remove one Bolt and slide the EVAP Canister rearward to remove it from the vehicle (see Figure 20).
EVAP Canister Installation
4. Install the EVAP Canister in the reverse order of removal, making sure:
^ All hoses are properly re-connected and securely attached.
^ The wire harness connectors are securely re-connected / snapped in place.
PROCEDURE C (EVAP Canister Inspection)
1. Hold the EVAP Canister with the open Ports facing downward (see Figure 21).
^ Check for liquid fuel coming out of the open Ports.
^ If liquid fuel drips out of any of the open Ports, replace the EVAP Canister.
^ If NO liquid fuel drips out of the open Ports, re-install the EVAP Canister.