13B-1

GROUP 13B

FUEL SUPPLY
CONTENTS

GENERAL INFORMATION . . . . . . . . 13B-2 FUEL LEVEL SENSOR CHECK . . . . . . . . . 13B-6

FUEL PUMP MODULE REPLACEMENT . . 13B-6
SERVICE SPECIFICATION . . . . . . . . 13B-2 FUEL LEVEL SENSOR (SUB) REPLACEMENT
<AWD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-9
FUEL SUPPLY DIAGNOSIS . . . . . . . 13B-2 FUEL TANK DIFFERENTIAL PRESSURE SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-11
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 13B-2
TROUBLESHOOTING STRATEGY . . . . . . 13B-2
FUEL TANK . . . . . . . . . . . . . . . . . . . . 13B-12
SYMPTOM PROCEDURES . . . . . . . . . . . . 13B-2
REMOVAL AND INSTALLATION <FWD>. . 13B-12
REMOVAL AND INSTALLATION <AWD> . 13B-17
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13B-5
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 13B-22
ON-VEHICLE SERVICE. . . . . . . . . . . 13B-6 DISASSEMBLY AND ASSEMBLY <FWD> . 13B-23
DISASSEMBLY AND ASSEMBLY <AWD>. 13B-25
FUEL PUMP OPERATION CHECK . . . . . . 13B-6
DISASSEMBLY AND ASSEMBLY . . . . . . . 13B-27
13B-2 FUEL SUPPLY
GENERAL INFORMATION

GENERAL INFORMATION
M1135000101449
• The fuel tank is mounted underneath the rear • A fuel tank safety valve, which prevents fuel leak-
seat to improve safety at a collision. age when the vehicle banks or rolls over, is
• The fuel tank itself is made of a pre-coat galva- located inside the fuel tank for fewer openings
nized steel sheet that contains no lead. and hose bonding points on the fuel tank top sur-
• The capacity of the fuel tank is 63 dm3 (16.6 gal) face.
• A built-in fuel tank filter and a fuel tank suction
<FWD> or 60 dm3 (15.8 gal) <AWD> to meet
hose have been adopted to meet the fuel tank of
long-distance drives.
a saddleback shape <AWD>.

SERVICE SPECIFICATION
M1135000300387

Item Standard value

Fuel tank differential pressure sensor output voltage V 2.0 − 3.0

FUEL SUPPLY DIAGNOSIS

INTRODUCTION
M1135004000504
The fuel system is used to supply an appropriate fuel Engine malfunctions caused by insufficient fuel sup-
mixture to the engine. The system consists of the ply and evaporative emission system operation mal-
fuel tank, fuel filter, fuel pump and fuel pipes. An functions can be caused by faults in the vapor line,
evaporative emission system is provided to prevent fuel pipe, hose, or fuel tank pressure control valve,
evaporated fuel from escaping into the atmosphere. etc.
TROUBLESHOOTING STRATEGY
M1135004100437
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure to find customer exists.
most of the fuel supply faults. 3. Find the malfunction by following the Symptom
1. Gather information from the customer. Procedure.
4. Verify malfunction is eliminated.
SYMPTOM PROCEDURES
M1135004800492

Inspection Procedure 1 : Engine Malfunctions Due to Insufficient Fuel Supply

TROUBLESHOOTING HINTS (The most likely causes for

this case:)
• Fuel injector failed.
• Open or shorted fuel injector circuit, or loose connector.
• Bent, twisted or clogged fuel main pipe or fuel high-pres-
sure tube.
• Malfunction of the fuel pump module.

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 FUEL SUPPLY
FUEL SUPPLY DIAGNOSIS
13B-3
DIAGNOSIS

STEP 1. Using scan tool MB991958, read the MFI system

diagnostic trouble code.
CAUTION
To prevent damage to scan tool MB991958, always turn the
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991958.
(1) Ensure that the ignition switch is at the "LOCK" (OFF)
position.
(2) Start up the personal computer.
(3) Connect special tool MB991827 to special tool MB991824
and the personal computer.
(4) Connect special tool MB991910 to special tool MB991824.
(5) Connect special tool MB991910 to the data link connector.
(6) Turn the power switch of special tool MB991824 to the "ON"
position.
NOTE: When special tool MB991824 is energized, special
tool MB991824 indicator light will be illuminated in a green
color.
(7) Start the M.U.T.-III system on the personal computer.
(8) Turn the ignition switch to the "ON" position.
(9) Check for MFI system diagnostic trouble code (Refer to
GROUP 13A, Diagnostic Function − How to Read and
Erase Diagnostic Trouble Codes P.13A-11).
(10)Turn the ignition switch to the "LOCK" (OFF) position, and
then remove scan tool MB991958 in the reverse order of
installation.
Q: Is the DTC set?
YES : Repair MFI system (Refer to GROUP 13A, Diagnostic
Trouble Code Chart P.13A-50). Then go to Step 6.
NO : Go to Step 2.

STEP 2. Check the fuel pressure.

Release residual pressure from the fuel line to prevent fuel
spray (Refer to GROUP 13A, On-vehicle Service − Fuel Pres-
sure Test P.13A-1018).
Q: Is the fuel pressure in good condition?
YES : Go to Step 5.
NO : Go to Step 3.

STEP 3. Check for bending, twisting or clogging of the fuel

main pipe and fuel high-pressure hose.
Q: Are the fuel main pipe and fuel high-pressure hose in
good condition?
YES : Go to Step 4.
NO : Repair or replace the fuel main pipe or fuel
high-pressure hose. Then go to Step 6 .

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13B-4 FUEL SUPPLY
FUEL SUPPLY DIAGNOSIS

STEP 4. Check the fuel pump module operation.

Refer to GROUP 13A, On-vehicle Service − Fuel Pump Opera-
tion Check P.13A-1022.
Q: Is the fuel pump module operation in good condition?
YES : Go to Step 5.
NO : Replace the fuel pump module (Refer to P.13B-6).
Then go to Step 6.

STEP 5. Check the inside of the fuel tank for contamination

and rust.
(1) Drain fuel.
(2) Remove the fuel tank (Refer to P.13B-12) <FWD>, (Refer to
P.13B-17) <AWD>.
Q: Is the fuel tank in good condition?
YES : Go to Step 6.
NO : Replace the fuel filter, and clean the fuel tank and fuel
line. Then go to Step 6 .

STEP 6. Retest the system.

Q: Is the engine malfunction eliminated?
YES : The procedure is complete.
NO : Return to Step 1.

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 FUEL SUPPLY
SPECIAL TOOLS
13B-5
SPECIAL TOOLS
M1135000601240

Tool Tool number and name Supersession Application

MB991958 MB991824-KIT CAUTION
a
Scan tool (M.U.T.-III sub NOTE: MB991826 For vehicles with CAN
assembly) M.U.T.-III Trigger communication, use M.U.T.-III
a: MB991824 Harness is not main harness A to send
Vehicle necessary when simulated vehicle speed. If
MB991824
communication pushing V.C.I. you connect M.U.T.-III main
b interface (V.C.I.) ENTER key. harness B instead, the CAN
b: MB991827 communication does not
M.U.T.-III USB cable function correctly.
c: MB991910 Checking diagnostic trouble
M.U.T.-III main codes
MB991827
harness A (Vehicles
c
with CAN
communication
system)
d: MB991911
MB991910 M.U.T.-III main
d harness B (Vehicles
without CAN
DO NOT USE communication
system)
e: MB991914
MB991911
M.U.T.-III main
e harness C (for
Chrysler models only)
DO NOT USE f: MB991825
M.U.T.-III adapter
MB991914 harness
g: MB991826
f
M.U.T.-III trigger
harness

MB991825

MB991826
MB991958

MB991658 Tool not available Fuel tank differential pressure

Test harness set sensor check

MB991658

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13B-6 FUEL SUPPLY
ON-VEHICLE SERVICE

ON-VEHICLE SERVICE
FUEL PUMP OPERATION CHECK
M1135001000969
Refer to GROUP 13A, On-vehicle Service − Fuel Pump Opera-
tion Check P.13A-1022.

FUEL LEVEL SENSOR CHECK

M1135005300177
Refer to GROUP 54A, Combination Meter − On-vehicle Service
− Fuel Level Sensor Check P.54A-116.

FUEL PUMP MODULE REPLACEMENT

M1135004901931
1. Remove the rear seat cushion assembly (Refer to GROUP
52A, Rear Seat Assembly P.52A-49) and turn up the floor
carpet.
2. Remove the floor inspection lid (LH).
Floor inspection lid (LH)

ACA00093AB

Fuel tank differential AC506219 3. Disconnect the fuel pump module connector and fuel tank
pressure sensor differential pressure sensor connector.
connector 4. Release the fuel pressure in the fuel line (Refer to GROUP
13A, On-vehicle Service - Reduce Pressurized Fuel Lines
P.13A-1021).

Fuel pump
module Fuel main pipe
connector AC703470 AB

Flat-tip
5. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm
screwdriver (0.04 inch) thick] into the retainer of the fuel main pipe.
Retainer

Fuel main pipe

Fuel pump module AC606017AC

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 FUEL SUPPLY
ON-VEHICLE SERVICE
13B-7
CAUTION
When pushing up the retainer of the fuel main pipe con-
nector, pay attention to avoid damage to the retainer.
6. Turn the flat-tip screwdriver inserted into the retainer by 90
Flat-tip screwdriver degrees to push up the retainer and unlock the fuel main
Retainer pipe connector.
7. Disconnect the fuel main pipe from the fuel pump module.

Fuel main pipe

Fuel pump module AC606018 AC

Fuel pump module 8. Remove the mounting nuts of fuel pump module.
9. Remove the plate.

AC703471AB

CAUTION
Pay attention not to damage the fuel gauge unit and float
of the fuel pump module when removing the fuel pump
module from the fuel tank.
10.Remove the fuel pump module from service hole <FWD>.
CAUTION
Pay attention not to damage the fuel gauge unit and float
of the fuel pump module when removing the fuel pump
module from the fuel tank.
11.While removing the fuel pump module from service hole,
Fuel pump module disconnect the fuel tank suction hose, and remove the fuel
pump module from service hole completely <AWD>.
12.Replace the fuel pump module gasket with a new one.
CAUTION
• Pay attention not to damage the fuel gauge unit and the
float of the fuel pump module when installing it to the
Suction hose fuel tank.
• When installing the fuel pump module to the fuel tank,
AC506221AD
check that the fuel gauge unit moving area moves
smoothly.
13.Install the fuel pump module to the fuel tank through the
service hole <FWD>.

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13B-8 FUEL SUPPLY
ON-VEHICLE SERVICE

CAUTION
• When installing the fuel pump module into the fuel tank
from the service hole, be careful not to damage the
gauge unit and the float. In addition, be careful that the
float does not catch the fuel tank suction hose in the
fuel tank.
• When installing the fuel pump module to the fuel tank,
check that the fuel gauge unit moving area moves
smoothly.
14.While inserting the fuel pump module from the service hole
Fuel pump module to fuel tank, connect the fuel tank suction hose and install
the fuel pump module in the fuel tank <AWD>.
15.Install the plate.

Suction hose

AC506221AD

Fuel pump module 16.Tighten the fuel pump module mounting nuts to the
specified torque.
Tightening torque: 2.5 ± 0.4 N⋅m (22 ± 4 in-lb)

AC703471AB

17.Pull up the retainer of fuel main pipe to unlock before

Retainer installing.

Fuel main pipe

AC606019 AE

18.Connect the connector of fuel main pipe to the fuel pump

Retainer module securely and push down the retainer of the
connector to lock it firmly.
19.After the installation, slightly pull the fuel main pipe to check
that it is connected securely. At this time, also check that
there is approximately 1 mm (0.04 inch) play.

Fuel pump module Fuel main pipe

AC703460AB

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 FUEL SUPPLY
ON-VEHICLE SERVICE
13B-9
Fuel tank differential AC506219 20.Connect the fuel pump module connector and fuel tank
pressure sensor differential pressure sensor connector.
connector

Fuel pump
module Fuel main pipe
connector AC703470 AB

21.Install the floor inspection lid (LH).

Floor inspection lid (LH)
22.Return the floor carpet to the original condition and install
the rear seat cushion assembly (Refer to GROUP 52A, Rear
Seat Assembly P.52A-49).

ACA00093AB

FUEL LEVEL SENSOR (SUB) REPLACEMENT

<AWD>
M1135005500063
1. Remove the rear seat cushion assembly (Refer to GROUP
52A, Rear Seat Assembly P.52A-49) and turn up the floor
carpet.
2. Remove the floor inspection lid (RH).
Floor inspection lid (RH)

ACA00110AC

3. Disconnect the fuel level sensor (sub) connector.

Fuel level sensor (sub) connector

AC506222AE

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13B-10 FUEL SUPPLY
ON-VEHICLE SERVICE

CAUTION
Pay attention not to damage the gauge unit and the float of
the fuel level sensor (sub) when withdrawing it from the
service hole.
4. Remove the fuel level sensor (sub) mounting nuts, and
Fuel level sensor (sub) remove the fuel level sensor (sub) from service hole.
5. Replace the fuel level sensor (sub) gasket with a new one.

AC506223AC

CAUTION
Pay attention not to damage the gauge unit and the float of
the fuel level sensor (sub) when installing it to the fuel tank
through the service hole.
6. Install the fuel level sensor (sub) to the fuel tank through the
Fuel level sensor (sub) service hole, and tighten the mounting nuts to the specified
torque.
Tightening torque: 2.5 ± 0.4 N⋅m (22 ± 4 in-lb)

AC506223AC

7. Connect the connectors of the fuel level sensor (sub).

Fuel level sensor (sub) connector

AC506222AE

8. Install the floor inspection lid (RH).

Floor inspection lid (RH) 9. Return the floor carpet to the original condition and install
the rear seat cushion assembly (Refer to GROUP 52A, Rear
Seat Assembly P.52A-49).

ACA00110AC

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 FUEL SUPPLY
ON-VEHICLE SERVICE
13B-11
FUEL TANK DIFFERENTIAL PRESSURE SENSOR
CHECK
M1135003200204

Requird Special Tool:

• MB991658: Test Harness Set
1. Remove the rear seat cushion assembly (Refer to GROUP
52A, Rear Seat Assembly P.52A-49) and turn up the floor
carpet.
2. Remove the floor inspection lid (LH).
Floor inspection lid (LH)

ACA00093AB

Fuel tank differential AC506219 3. Disconnect the fuel tank differential pressure sensor
pressure sensor connector.
connector

Fuel pump
module Fuel main pipe
connector AC703470 AB

Fuel tank differential 4. Connect special tool MB991658 between the terminals of
pressure sensor the disconnected connector.
connector 5. Turn the ignition switch to “ON” position and measure the
voltage between terminal 1 and ground.
Standard value: 2.0 − 3.0 V
6. If not within the standard value, replace the fuel tank
differential pressure sensor.

MB991658
AC703476AC

Fuel tank differential AC506219 7. Connect the fuel tank differential pressure sensor connector.
pressure sensor
connector

Fuel pump
module Fuel main pipe
connector AC703470 AB

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13B-12 FUEL SUPPLY
FUEL TANK

8. Install the floor inspection lid (LH).

Floor inspection lid (LH)
9. Return the floor carpet to the original condition and install
the rear seat cushion assembly (Refer to GROUP 52A, Rear
Seat Assembly P.52A-49).

ACA00093AB

FUEL TANK
REMOVAL AND INSTALLATION <FWD>
M1135001903994

Pre-removal Operation Post-installation Operation

• Rear Seat Cushion Assembly Removal (Refer to GROUP • Rear Seat Cushion Assembly Installation (Refer to
52A, Rear Seat Assembly P.52A-49). GROUP 52A, Rear Seat Assembly P.52A-49).
• Fuel Line Pressure Reduction (Refer to GROUP 13A, • Exhaust Center Pipe Installation (Refer to GROUP 15,
On-vehicle Service − Reduce Pressurized Fuel Lines Exhaust Pipe and Main Muffler P.15-14).
P.13A-1021). • Fuel Refilling.
• Fuel Draining. • Fuel Leak Check.
• Exhaust Center Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-14).

<FUEL TANK>

1 3
6
5 7
11

8
4
2

22 ± 5 N·m
16 ± 4 ft-lb 10
41 ± 10 N·m
31 ± 7 ft-lb

13 ± 2 N·m
111 ± 22 in-lb 41 ± 10 N·m
31 ± 7 ft-lb
13 ± 2 N·m
111 ± 22 in-lb 9
ACA02921AB

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 FUEL SUPPLY
FUEL TANK
13B-13
Fuel tank removal steps Fuel tank removal steps
<<A>> 1. Fuel pump module connector 7. Fuel tank vapor hose A
<<A>> 2. Fuel tank differential pressure connection
sensor connector 8. Fuel tank vapor hose B
<<A>> >>C<< 3. Fuel main pipe connection connection
>>B<< 4. Hose clamp 9. Parking brake rear cable clamp
5. Fuel filler hose connection connection
6. Fuel leveling hose connection <<B>> 10. Fuel tank band
<<B>> 11. Fuel tank assembly

<FUEL TANK FILLER TUBE>

11

13

12
7

3 4

6N
10
20 ± 5 N·m
15 ± 3 ft-lb

2 5 9
1
20 ± 5 N·m
20 ± 5 N·m
15 ± 3 ft-lb
15 ± 3 ft-lb
8
ACA02925 AB

Fuel tank filler tube removal Fuel tank filler tube removal
steps steps (Continued)
>>B<< 1. Hose clamp 7. Fuel filler hose protector
2. Fuel filler hose connection 8. Fuel vapor tube connection
3. Fuel leveling hose connection 9. Fuel leveling pipe
4. Fuel tank vapor hose A 10. Fuel leveling hose
connection 11. Fuel cap
5. Fuel tank vapor hose B 12. Fuel tank filler tube assembly
connection 13. Fuel tank filler tube boots
<<C>> >>A<< 6. Rivet

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13B-14 FUEL SUPPLY
FUEL TANK

REMOVAL SERVICE POINTS

.

<<A>> FUEL PUMP MODULE CONNECTOR/FUEL

TANK DIFFERENTIAL PRESSURE SENSOR CON-
NECTOR/FUEL MAIN PIPE DISCONNECTION
1. Remove the floor inspection lid (LH).
Floor inspection lid (LH)

ACA00093AB

Fuel tank differential AC506219 2. Disconnect the fuel pump module connector and fuel tank
pressure sensor differential pressure sensor connector.
connector 3. Release the fuel pressure in the fuel line (Refer to GROUP
13A, On-vehicle Service - Reduce Pressurized Fuel Lines
P.13A-1021).

Fuel pump
module Fuel main pipe
connector AC703470 AB

4. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm

Flat-tip
screwdriver (0.04 inch) thick] into the retainer of the fuel main pipe.
Retainer

Fuel pump module Fuel main pipe

AC703457AB

5. Turn the flat-tip screwdriver about 90 degrees to push up the

Flat-tip screwdriver retainer, and disconnect the fuel main pipe from the fuel
Retainer
pump module.

Fuel pump module Fuel main pipe

AC703458AB

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 FUEL SUPPLY
FUEL TANK
13B-15
<<B>> FUEL TANK BAND/FUEL TANK ASSEMBLY
REMOVAL
1. Hold the fuel tank assembly with the transmission jack, and
remove the connecting bolts of fuel tank band and the
connecting nuts of fuel tank assembly.
2. Remove the fuel tank assembly.

Fuel tank
assembly
AC506457AB

<<C>> RIVET REMOVAL

CAUTION
Be careful not to score the heat protector by drill.
Use a 6.0 / diameter / mm drill to make a hole in the rivet to
Fuel filler break it, and then remove the rivet.
hose Rivet
protector

Drill

AC301909AH

INSTALLATION SERVICE POINTS

.

>>A<< RIVET INSTALLATION

Use a rivet tool shown in the illustration to connect the parts
Rivet tool
with rivets by the following procedures.
1. Insert the rivet into a corresponding location.
2. Set the rivet tool at a portion A of rivet.
3. While pushing the flange surface of the rivet onto parts to be
fixed with the rivet tool, press the handle of the tool.
Fixing parts
Fuel filler hose protector
4. Thin part of portion A of the rivet will be cut off and the parts
is fixed in position.
Portion A

1
Rivet

3 Rivet tool

Flange

Rivet
AC700168 AC

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13B-16 FUEL SUPPLY
FUEL TANK

>>B<< HOSE CLAMP INSTALLATION

Connect the fuel filler hose, and tighten the bolt of hose clamp
so that the bolt tightening dimension of the hose clump
becomes 4.5 ± 1.5 mm (0.18 ± 0.06 inch).

Hose clamp

4.5 ± 1.5 mm
(0.18 ± 0.06 in)
AC707593AJ

>>C<< FUEL MAIN PIPE CONNECTION

1. Pull up the retainer of fuel main pipe to unlock before
Retainer installing.

Fuel main pipe

AC606019 AE

CAUTION
• When pushing in the retainer of the fuel main pipe con-
nector, pay attention to avoid damage to the retainer.
• After the installation of the fuel high-pressure hose,
slightly pull the fuel high-pressure hose to check that it
is connected securely. At this time, also check that
there is approximately 1 mm (0.04 inch) play.
2. Install the fuel main pipe to the fuel pump module securely
Retainer and push in the retainer of the fuel main pipe connector to
lock the fuel main pipe and fuel pump module.

Fuel pump module Fuel main pipe

AC606020AC

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 FUEL SUPPLY
FUEL TANK
13B-17
REMOVAL AND INSTALLATION <AWD>
M1135001904005

Pre-removal Operation Post-installation Operation

• Rear Seat Cushion Assembly Removal (Refer to GROUP • Rear Seat Cushion Assembly Installation (Refer to
52A, Rear Seat Assembly P.52A-49). GROUP 52A, Rear Seat Assembly P.52A-49).
• Fuel Line Pressure Reduction (Refer to GROUP 13A, • Exhaust Center Pipe Installation (Refer to GROUP 15,
On-vehicle Service − Reduce Pressurized Fuel Lines Exhaust Pipe and Main Muffler P.15-14).
P.13A-1021). • Propeller Shaft Installation (Refer to GROUP 25, Propeller
• Fuel Draining. Shaft P.25-6).
• Propeller Shaft Removal (Refer to GROUP 25, Propeller • Fuel Refilling.
Shaft P.25-6). • Fuel Leak Check.
• Exhaust Center Pipe Removal (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-14).

<FUEL TANK>
4 1
3
7
12 6 8

9
5
2

22 ± 5 N·m
16 ± 4 ft-lb
41 ± 10 N·m
31 ± 7 ft-lb 11

10

13 ± 2 N·m 41 ± 10 N·m
111 ± 22 in-lb 31 ± 7 ft-lb

13 ± 2 N·m
111 ± 22 in-lb
10
ACA02923 AB

Fuel tank removal steps Fuel tank removal steps

<<A>> 1. Fuel pump module connector • Rear suspension crossmember
<<A>> 2. Fuel tank differential pressure stay (Refer to GROUP 34, Rear
sensor connector Suspension Crossmember
<<A>> >>C<< 3. Fuel main pipe connection P.34-26)
<<B>> 4. Fuel level sensor (sub) connector • Electronic control coupling
>>B<< 5. Hose clamp harness cover (Refer to GROUP
6. Fuel filler hose connection 27C, Electronic Control AWD
7. Fuel leveling hose connection P.27C-95)
8. Fuel tank vapor hose A <<C>> • Electronic control coupling
connection harness connector and harness
9. Fuel tank vapor hose B clamp connection
connection <<C>> • Differential mount bracket
10. Parking brake rear cable clamp mounting bolt
connection <<C>> 11. Fuel tank band
<<C>> 12. Fuel tank assembly

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13B-18 FUEL SUPPLY
FUEL TANK

<FUEL TANK FILLER TUBE>

11

13

12
7

3 4

6N
10
20 ± 5 N·m
15 ± 3 ft-lb

2 5 9
1
20 ± 5 N·m
20 ± 5 N·m
15 ± 3 ft-lb
15 ± 3 ft-lb
8
ACA02925 AB

Fuel tank filler tube removal Fuel tank filler tube removal
steps steps (Continued)
>>B<< 1. Hose clamp 7. Fuel filler hose protector
2. Fuel filler hose connection 8. Fuel vapor tube connection
3. Fuel leveling hose connection 9. Fuel leveling pipe
4. Fuel tank vapor hose A 10. Fuel leveling hose
connection 11. Fuel cap
5. Fuel tank vapor hose B 12. Fuel tank filler tube assembly
connection 13. Fuel tank filler tube boots
<<D>> >>A<< 6. Rivet

REMOVAL SERVICE POINTS

.

<<A>> FUEL PUMP MODULE CONNECTOR/FUEL

TANK DIFFERENTIAL PRESSURE SENSOR CON-
NECTOR/FUEL MAIN PIPE DISCONNECTION
1. Remove the floor inspection lid (LH).
Floor inspection lid (LH)

ACA00093AB

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 FUEL SUPPLY
FUEL TANK
13B-19
Fuel tank differential AC506219 2. Disconnect the fuel pump module connector and fuel tank
pressure sensor differential pressure sensor connector.
connector 3. Release the fuel pressure in the fuel line (Refer to GROUP
13A, On-vehicle Service - Reduce Pressurized Fuel Lines
P.13A-1021).

Fuel pump
module Fuel main pipe
connector AC703470 AB

4. Insert a flat-tip screwdriver [6 mm (0.24 inch) wide and 1 mm

Flat-tip
screwdriver (0.04 inch) thick] into the retainer of the fuel main pipe.
Retainer

Fuel pump module Fuel main pipe

AC703457AB

5. Turn the flat-tip screwdriver about 90 degrees to push up the

Flat-tip screwdriver retainer, and disconnect the fuel main pipe from the fuel
Retainer
pump module.

Fuel pump module Fuel main pipe

AC703458AB

<<B>> FUEL LEVEL SENSOR (SUB) CONNECTOR

DISCONNECTION
1. Remove the floor inspection lid (RH).
Floor inspection lid (RH)

ACA00110AC

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13B-20 FUEL SUPPLY
FUEL TANK

2. Disconnect the fuel level sensor (sub) connector.

Fuel level sensor (sub) connector

AC506222AE

<<C>> ELECTRONIC CONTROL COUPLING

HARNESS CONNECTOR AND HARNESS
CLAMP/DIFFERENTIAL MOUNT BRACKET
MOUNTING BOLT/FUEL TANK BAND/FUEL TANK
ASSEMBLY REMOVAL
Electronic control 1. Disconnect the electronic control coupling connector, the
coupling harness clamp wiring harness clamp and the breather hose at the rear
Electronic control
coupling harness differential carrier (Refer to GROUP 27C, Electronic Control
connector, breather hose Coupling P.27C-95).
Rear differential
carrier assembly 2. Remove the differential mount bracket bolts, and tilt the
differential carrier to hold it on a support stand (Refer to
GROUP 27B, Rear Axle P.27B-26).

Assistance stand AC904771AE

3. Support the fuel tank assembly on a transmission jack, and

then remove the fuel tank band securing bolts and the fuel
tank assembly connecting nuts.
4. Remove the fuel tank assembly while holding its tilted
position and taking care not to strike it with the differential
carrier.

Fuel tank
assembly
AC506457AB

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 FUEL SUPPLY
FUEL TANK
13B-21
<<D>> RIVET REMOVAL
CAUTION
Be careful not to score the heat protector by drill.
Use a 6.0 / diameter / mm drill to make a hole in the rivet to
Fuel filler break it, and then remove the rivet.
hose Rivet
protector

Drill

AC301909AH

INSTALLATION SERVICE POINTS

.

>>A<< RIVET INSTALLATION

Use a rivet tool shown in the illustration to connect the parts
Rivet tool
with rivets by the following procedures.
1. Insert the rivet into a corresponding location.
2. Set the rivet tool at a portion A of rivet.
3. While pushing the flange surface of the rivet onto parts to be
fixed with the rivet tool, press the handle of the tool.
Fixing parts
Fuel filler hose protector
4. Thin part of portion A of the rivet will be cut off and the parts
is fixed in position.
Portion A

1
Rivet

3 Rivet tool

Flange

Rivet
AC700168 AC

>>B<< HOSE CLAMP INSTALLATION

Connect the fuel filler hose, and tighten the bolt of hose clamp
so that the bolt tightening dimension of the hose clump
becomes 4.5 ± 1.5 mm (0.18 ± 0.06 inch).

Hose clamp

4.5 ± 1.5 mm
(0.18 ± 0.06 in)
AC707593AJ

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13B-22 FUEL SUPPLY
FUEL TANK

>>C<< FUEL MAIN PIPE CONNECTION

1. Pull up the retainer of fuel main pipe to unlock before
Retainer installing.

Fuel main pipe

AC606019 AE

CAUTION
• When pushing in the retainer of the fuel main pipe con-
nector, pay attention to avoid damage to the retainer.
• After the installation of the fuel high-pressure hose,
slightly pull the fuel high-pressure hose to check that it
is connected securely. At this time, also check that
there is approximately 1 mm (0.04 inch) play.
2. Install the fuel main pipe to the fuel pump module securely
Retainer and push in the retainer of the fuel main pipe connector to
lock the fuel main pipe and fuel pump module.

Fuel pump module Fuel main pipe

AC606020AC

INSPECTION
M1135002000489
.

FUEL SHUT-OFF VALVE CHECK

Check that the flapper of the fuel shut-off valve opens and
Fuel shut-off valve
Flapper closes as shown in the illustration.

Open

80˚

Closed
AC703475AB

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 FUEL SUPPLY
FUEL TANK
13B-23
DISASSEMBLY AND ASSEMBLY <FWD>
M1135006800647

<FUEL TANK ASSEMBLY>

2.5 ± 0.4 N·m
22 ± 4 in-lb
1

3N 6

8
11
5
9 4

10

ACA02922 AB

Disassembly steps Disassembly steps (Continued)

1. Plate 7. Fuel tank vapor hose A
<<A>> >>B<< 2. Fuel pump module 8. Fuel tank vapor hose B
3. Fuel pump module gasket 9. Fuel shut-off valve
>>A<< 4. Hose clamp 10. Fuel tank lower protector
5. Fuel filler hose 11. Fuel tank
6. Fuel leveling hose

DISASSEMBLY SERVICE POINT

.

<<A>> FUEL PUMP MODULE REMOVAL

CAUTION
Pay attention not to damage the fuel level sensor and float
of the fuel pump module when removing the fuel pump
module from the fuel tank.

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13B-24 FUEL SUPPLY
FUEL TANK

ASSEMBLY SERVICE POINTS

.

>>A<< HOSE CLAMP INSTALLATION

After connecting the fuel filler hose, tighten the bolts of hose
clamp so that the tightening dimension is 4.5 ± 1.5 mm (0.18 ±
0.06 inch).
4.5 ± 1.5 mm
(0.18 ± 0.06 in)

Hose clamp

ACA00101AC

>>B<< FUEL PUMP MODULE INSTALLATION

CAUTION
• Pay attention not to damage the fuel level sensor and
the float of the fuel pump module when installing it to
the fuel tank.
• When installing the fuel pump module to the fuel tank,
check that the fuel level sensor moving area moves
smoothly.

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 FUEL SUPPLY
FUEL TANK
13B-25
DISASSEMBLY AND ASSEMBLY <AWD>
M1135006800658

<FUEL TANK ASSEMBLY>

2.5 ± 0.4 N·m

22 ± 4 in-lb
1
2.5 ± 0.4 N·m
22 ± 4 in-lb

5
2
N 6
3
9
4N
10
14

11
8
12 7

13

ACA02924 AB

Disassembly steps Disassembly steps (Continued)

1. Plate 8. Fuel filler hose
<<A>> >>C<< 2. Fuel tank suction hose connector 9. Fuel leveling hose
<<A>> >>C<< 3. Fuel pump module 10. Fuel tank vapor hose
4. Fuel pump module gasket 11. Fuel tank vapor hose
<<B>> >>B<< 5. Fuel level sensor (sub) 12. Fuel shut-off valve
6. Fuel level sensor (sub) gasket 13. Fuel tank lower protector
>>A<< 7. Hose clamp 14. Fuel tank

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13B-26 FUEL SUPPLY
FUEL TANK

DISASSEMBLY SERVICE POINTS

.

<<A>> FUEL TANK SUCTION HOSE DISCONNEC-

TION/FUEL PUMP MODULE REMOVAL
CAUTION
When removing the fuel pump module from the fuel tank,
be careful not to damage the gauge unit and float of fuel
pump module.
While removing the fuel pump module form the fuel tank, dis-
Fuel pump module connect the fuel tank suction hose from the fuel pump module,
and remove the fuel pump module form the fuel tank.

Suction hose

AC506221AD

<<B>> FUEL LEVEL SENSOR (SUB) REMOVAL

CAUTION
When removing the fuel level sensor (sub) from the fuel
tank, be careful not to damage the gauge unit and float of
fuel level sensor (sub).

ASSEMBLY SERVICE POINTS

.

>>A<< HOSE CLAMP INSTALLATION

After connecting the fuel filler hose, tighten the bolts of hose
clamp so that the tightening dimension is 4.5 ± 1.5 mm (0.18 ±
0.06 inch).
4.5 ± 1.5 mm
(0.18 ± 0.06 in)

Hose clamp

ACA00101AC

>>B<< FUEL LEVEL SENSOR (SUB)

INSTALLATION
CAUTION
When installing the fuel level sensor (sub) into the fuel
tank, be careful not to damage the gauge unit and float of
fuel level sensor (sub).
.

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 FUEL SUPPLY
FUEL TANK
13B-27
>>C<< FUEL PUMP MODULE/FUEL TANK
SUCTION HOSE CONNECTION INSTALLATION
CAUTION
• When installing the fuel pump module into the fuel tank
from the service hole, be careful not to damage the
gauge unit and the float of the fuel pump module. In
addition, be careful that the float does not catch the
fuel tank suction hose in the fuel tank.
• When installing the fuel pump module into the fuel tank
from the service hole, check that the moving part of the
gauge works smoothly.
While inserting the fuel pump module into the fuel tank from the
Fuel pump module service hole, connect the fuel tank suction hose, and install the
fuel pump module to the fuel tank.

Suction hose

AC506221AD

DISASSEMBLY AND ASSEMBLY

M1135004601792

<FUEL PUMP MODULE>

NOTE: For installation and removal, refer to Fuel
Pump Module Replacement in On-vehicle Service
(refer to P.13B-6.)

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13B-28 FUEL SUPPLY
FUEL TANK

N 2

6N

N 16

9N 12 N
10 N 13 N
N 15
14 N
3
11
8

5 7N

4N
ACA02930 AC

Disassembly steps Disassembly steps (Continued)

1. Fuel tank differential pressure >>A<< 9. O-ring
sensor 10. Spacer
>>A<< 2. O-ring 11. Fuel tank pump pressure
3. Fuel gauge unit regulator
4. Clip >>A<< 12. O-ring
5. Subtank assembly >>A<< 13. O-ring
6. Spring 14. Back up ring
7. Fuel filter 15. Bracket
8. Fuel pump assembly 16. Fuel flange and filter assembly

ASSEMBLY SERVICE POINT

.

>>A<< O-RING INSTALLATION

To avoid twisting and damage, apply gasoline before installa-
tion of the O-ring.

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