Service Procedure

This service program will involve permanent removal of the fuel tank one-way fuel valve.

If an affected vehicle arrives at the dealer with the "Check Engine" light illuminated, the cause should be diagnosed. If diagnostic trouble code P0420 is found, replace the catalytic converter following the repair procedure outlined in the applicable Service Manual. Clear
code and proceed to the next step.

NOTE:
The catalytic converter should ONLY be replaced in conjunction with this Service Program when DTC P0420 is found.

WARNING:

^ Place "Caution" signs near the work area indicating "No Fire" or "No Smoking".

^ Be careful not to spill fuel on the floor.

^ Make sure there is no more than half a tank of fuel in fuel tank.

Fuel Pump Housing & One-Way Fuel Valve Removal

Caution:
Use extreme care while performing the following steps. Gasoline contained in the fuel tank is extremely flammable. Repairs should only be performed in a well ventilated area.

^ Do not use electrical devices, such as drop lights, or other items that could cause a spark.

^ Do not allow smoking or other activities in the work area that could result in ignition of fuel vapors.

^ Be sure the vehicle's battery is disconnected, as indicated in the following instructions.

1) Remove the luggage area floor mat (varies by model).

^ Remove the backside mat from the rear seat backrest.





^ Remove the clips and then detach the rear floor mats and boxes.





2) Remove fuel pump access cover.

3) Release fuel pressure:





^ Disconnect the electrical connector from fuel pump.

^ Start the engine and run it until it stalls.

^ After the engine stalls, crank it for five more seconds.

^ Turn ignition switch to OFF.

NOTE:
Record radio pre-set stations.





4) Disconnect battery ground cable.





5) Please use caution and observe the following instructions when separating the fuel pump line connections. Note: The fuel line retainer clamps used on lines "A", "B" and "C" will be reused so take care not to cause damage during disassembly. (Configurations and clamp type vary by model.)





Separation of the Quick Connector on the Fuel Pump





The special tool 42099AE000, which is set up to separate fuel hoses with quick connectors in the engine compartment, can also be used for return and delivery sub hoses. The quick connector can be unlocked by inserting the special tool around the pipe and pushing it forward as shown. Pull out and separate the connector.





6) Remove the nuts which secure the fuel pump assembly onto the fuel tank.

7) Carefully remove the fuel pump assembly from fuel tank. To ease removal, lift up on the float while removing. Do not attempt to force the pump assembly from the tank.





8) Wearing suitable fuel resistant gloves, reach into the fuel tank and remove the one-way fuel valve by pulling while twisting the valve. The valve should easily detach from the inner tank fuel reservoir. Discard the valve as it is no longer needed.

Reinstall the Fuel Pump Housing

Important:

^ Always use a new gasket.

^ Ensure the sealing portion is free from fuel or foreign particles before installation.

1) Carefully reinstall the fuel pump housing into the fuel tank using caution while inserting the fuel level float through the fuel tank opening. It will be necessary to hold the float up to avoid interference with the inner tank fuel reservoir.





2) Tighten nuts in alphabetical sequence as shown to the specified torque.
Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)

3) Reattach the fuel lines. NOTE: If the fuel line retainer clamps are damaged or broken, replace with new ones.

^ When the connector is reconnected, be careful not to force, bend, or twist the pipe.

When the retainer was separated using the special tool or the retainer was replaced with a new part:
Hold the connector body with your fingers, align the axis of the pipe and the connector and then push in the pipe until the retainer clicks.





^ Push and pull the connector lightly several times to ensure the pipe is fully engaged with the connector. Also, visually check if the retainer claws are engaged with the connector groove at both of the two points.

4) Reattach the fuel pump electrical connector.

5) Reconnect the battery.

6) Start vehicle and confirm there are no fuel leaks.

^ Raise fuel pressure in the high pressure fuel lines and check for leakage at each of the connectors, tubes and pipes.

7) Reinstall the fuel pump access cover and remaining components to their original condition.

8) Reprogram radio pre-set stations