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11-338Fuel Supply System
Fuel Pump/Fuel Gauge Sending Unit Replacement
A
B
C
1. Remove the fuel tank unit (see page 11-334).
2. Remove the fuel level sensor (fuel sending unit) (A)from the fuel tank unit (B).
3. Check these items before installing the fuel tank unit:
When connecting the wire harness, make sure the connection is secure and the connector (C) is
firmly locked into place.
When installing the fuel gauge sending unit, be careful not to bend or twist it excessively.
4. Install the parts in the reverse order of removal. When installing the fuel tank unit, align the marks
on the unit and the fuel tank (see page 11-335).
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DTC P0455:
DTC P0456:
Special Tools Required
YES
NO YES
NO
YES
NO
11-386EVAP System
DTC Troubleshooting (cont’d)
AB
C
EVAP System Large Leak
Detected
EVAP System Very Small Leak
Detected
The fuel system is designed to allow specified
maximum vacuum and pressure conditions. Do not
deviate from the vacuum and pressure tests as
indicated in these procedures. Excessive pressure/
vacuum would damage the EVAP components or
cause eventual fuel tank failure.
Vacuum pump/gauge, 0 30 in.Hg, Snap-on YA4000A
or equivalent, commercially available
NOTE: Before you troubleshoot, record all freeze data and any on-board snapshot, and review the general
troubleshooting information (see page 11-3).
Fresh fuel has a higher volatility that will create greater pressure/vacuum. The optimum condition for
testing is less than a full tank of fresh fuel. If possible,
to assist in leak detection, add 1 gallon of fresh fuel to
the tank (as long as it will not fill the tank), just before
starting these procedures.
1. Check the fuel fill cap (the cap must say TIGHTEN TO CLICK). It should turn 1/4 turn after it’s tight,
then it clicks.
Go to step 2.
Replace or tighten the cap, then go to step 30. 2. Check the fuel fill cap seal (A) and the fuel fill pipe
mating surface (B). Verify that the fuel fill cap tether
cord (C) is not caught under the cap.
Replace the fuel fill cap or the fuel fill pipe,
then go to step 29.
Go to step 3.
3. Turn the ignition switch to ON (II).
4. Clear the DTC with the HDS.
5. Do the EVAP FUNCTION TEST in the INSPECTION MENU with the HDS.
Intermittent failure, the system is OK at this
time. Check for poor connections or loose terminals
at the FTP sensor, the EVAP canister purge valve, or
the EVAP canister vent shut valve and the ECM/
PCM.
Go to step 6.
Is the correct f uel f ill cap installed and properlytightened? Is the f uel f ill cap seal missing or damaged, is the
f uel f i l l pi pe d amaged , or i s t he t et her cor d caughtund er the cap?
Is the result OK ?
08/08/21 14:32:36 61SNR030_110_0386
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YES
NO
YES
NO
11-387
AD
B C
D A
B
6. Turn the ignition switch to LOCK (0).
7. Check for a poor connection or damage at the fuel
tank vapor recirculation tube.
Go to step 8.
Replace the fuel tank vapor recirculation tube, then go to step 29.
If needed, replace the fuel tank (see page 11-339), then go to step 29.
8. Disconnect the fuel tank vapor recirculation tube (A) and the fresh air hose (B) from the EVAP
canister (C), and plug the EVAP canister ports (D). 9. Disconnect the vacuum hose (engine side) (A) from
the EVAP canister purge valve (B) in the engine
compartment, and connect a vacuum pump/gauge,
0 30 in.Hg, to the purge valve as shown.
10. Turn the ignition switch ON (II).
11. Select EVAP PCS ON in the INSPECTION MENU with the HDS.
12. Apply vacuum to the hose until the FTP reads 1.90 V ( 15.1 mmHg, 0.59 in.Hg).
NOTE: Be careful not to exceed the vacuum. If you
do, the FTP sensor can be damaged.
13. Select EVAP PCS OFF in the INSPECTION MENU with the HDS.
14. Monitor the FTP SENSOR in the DATA LIST for 1 minute with the HDS.
Go to step 15.
Go to step 22.
(cont’d)
*: This illustration shows K20Z2 engine.
IsthetubeOK?
Does the voltage increase more than 0.2 V( 0.5 mmH g, 0.1 i n.H g)?
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YES
NO YES
NO
YES
NO
11-389
A
B
C
23. Reconnect the vacuum hose (engine side) (A) to theEVAP canister purge valve (B) and disconnect the
vacuum hose (EVAP canister side) (C) from the
EVAP canister purge valve, then connect a vacuum
pump/gauge 0 30 in.Hg, to the vacuum hose as
shown.
24. Select EVAP CVS ON in the INSPECTION MENU with the HDS.
25. Apply vacuum to the EVAP system until the FTP reads 1.90 V ( 0.59 in.Hg, 15.1 mmHg).
NOTE: Be careful not to exceed the vacuum. If you
do, the FTP sensor can be damaged.
26. Monitor the FTP SENSOR in the DATA LIST for 1 minute with the HDS.
Replace the EVAP canister vent shut valve
(see page 11-409), then go to step 29.
Go to step 27.
27. Select EVAP CVS OFF in the INSPECTION MENU. 28. Check these parts for looseness or damage:
Fuel fill pipe
Fuel vapor return pipe
Check the fuel tank unit base gasket
(see page 11-335), and check the fuel tank, then go
to step 29.
Repair or replace the damaged parts, then go
to step 29.
29. Reconnect all hoses and connectors.
30. Turn the ignition switch to ON (II).
31. Reset the ECM/PCM with the HDS.
32. Do the ECM/PCM idle learn procedure (see page 11-310).
33. Do the EVAP FUNCTION TEST in the INSPECTION MENU with the HDS.
Troubleshooting is complete. If any other
Temporary DTCs or DTCs are indicated, go to the
indicated DTC’s troubleshooting.
Check for poor connections or loose terminals
at the FTP sensor, the EVAP canister purge valve,
the EVAP canister vent shut valve, and the ECM/
PCM, then go to step 1.
*: This illustration shows K20Z2 engine.
Does the voltage increase more than 0.2 V ( 2.5 mmH g, 0.1 i n.H g)? Ar e t he par t s OK ?
Is the result OK ?
08/08/21 14:32:38 61SNR030_110_0389
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DTC P0497:
Special Tools Required
YES
NO
YES
NO
YES
NO YES
NO
11-392EVAP System
DTC Troubleshooting (cont’d)
A
C
07JAZ-001000B
B
EVAP System Low Purge Flow
Detected
Vacuum/pressure gauge, 0 4 in.Hg, 07JAZ-001000B
Vacuum pump/gauge, 0 30 in.Hg, Snap-on YA4000A
or equivalent, commercially available
NOTE: Before you troubleshoot, record all freeze data
and any on-board snapshot, and review the general
troubleshooting information (see page 11-3). 1. Check the fuel fill cap installation (The cap must say TIGHTEN TO CLICK. The cap should tighten 1/4 turn
after it is tight.).
Go to step 2.
Properly install the fuel fill cap, then go to
step 23.
2. Turn the ignition switch to ON (II).
3. Clear the DTC with the HDS.
4. Do the EVAP FUNCTION TEST in the INSPECTION MENU with the HDS.
Intermittent failure, the system is OK at this
time. Check for poor connections or loose terminals
at the FTP sensor, the EVAP canister purge valve,
the EVAP canister vent shut valve, and the ECM/
PCM.
Go to step 5.
5. Check for a loose or damaged EVAP canister purge line between the intake manifold and the EVAP
canister purge valve.
Go to step 6.
Reconnect or repair the EVAP canister purge
line, then go to step 23. 6. Disconnect the vacuum hose (A) from the EVAP
canister purge valve (B) in the engine compartment,
and connect a T-fitting (C) between the vacuum
gauge, the vacuum pump/gauge, 0 30 in.Hg, and
the vacuum hose as shown.
7. Select EVAP PCS ON in the INSPECTION MENU with the HDS.
8. Slowly apply about 2 kPa (15 mmHg, 0.6 in.Hg) of vacuum to the hose.
Replace the EVAP canister purge valve, then
go to step 22.
Go to step 9.
Is the f uel f ill cap installed and properlytightened?
Is the result OK ?Is the line OK ? Does i t hol d v acuum?
08/08/21 14:33:20 61SNR030_110_0392
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Special Tools Required
YES
NO
YES
NO YES
NO
K20Z3 engine
11-405
Fuel Cap Warning Message System Troubleshooting
AB
C A
B
C 07JAZ-001000B
Vacuum/pressure gauge, 0 4 in.Hg 07JAZ-001000B
Vacuum pump/gauge, 0 30 in.Hg, Snap-on YA4000A
or equivalent, commercially available
Do this procedure if the fuel cap warning message
comes on frequently, or if the message does not go off
after the fuel fill cap is tightened and the vehicle is
driven several days.
1. Check the fuel fill cap (the cap must say TIGHTEN TO CLICK). It should turn 1/4 after it’s tight, then it
clicks.
Go to step 2.
Replace or tighten the cap, then go to step 13.
2. Check the fuel fill cap seal (A) and the fuel fill pipe mating surface (B). Verify that the fuel fill cap tether
cord (C) is not caught under the cap.
Replace the fuel fill cap or the fuel fill pipe,
then go to step 13.
Go to step 3. 3. Reinstall and tighten the fuel fill cap.
4. Clear the DTC with the HDS.
5. Start the engine. Hold the engine speed at
3,000 rpm without load (in neutral) until the
radiator fan comes on, then let it idle for 1 minute.
6. Test drive at 72 km/h (45 mph) for 1 minute or more.
Go to step 7.
Intermittent failure, the system is OK at this
time.
7. Turn the ignition switch to LOCK (0).
8. Disconnect the vacuum hose (A) from the EVAP canister purge valve (B) in the engine compartment,
and connect a T-fitting (C) between the vacuum
gauge and the vacuum pump/gauge 0 30 in.Hg,
and the EVAP canister purge valve as shown.
(cont’d)
Is the correct f uel f ill cap installed and properlytightened?
Is the f uel f ill cap seal missing or damaged, is thef uel f i l l pi pe d amaged , or i s t he t et her cor d caughtund er the cap? Does f uel cap w ar ni ng message come on?
08/08/21 14:33:26 61SNR030_110_0405
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Diagnostic Trouble Code (DTC)
Self-diagnosis
Kickback
Pump Motor
Brake Fluid Replacement/Air BleedingHow to Troubleshoot DTCs
Intermittent Failures
19-50
ABS Components
General Troubleshooting Information (cont’d)
The memory holds all DTCs. However, when the
same DTC is detected more than once, the more
recent DTC is written over the earlier one. Therefore,
when the same problem is detected repeatedly, it is
memorized as a single DTC.
The DTCs are indicated in the order they occur.
The DTCs are memorized in the EEPROM. Therefore, the memorized DTCs cannot be erased by
disconnecting the battery. Do the specified
procedures to clear the DTCs.
Self-diagnosis can be classified into two categories: – Initial diagnosis: Done right after the ignition switch is turned to ON (II) and until the ABS indicator goes
off.
– Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned to
LOCK (0).
When the system detects a problem, the ABS modulator-control unit shifts to fail-safe mode.
The pump motor operates when the ABS modulator-
control unit is functioning, and the fluid in the reservoir
is forced out to the master cylinder, causing kickback at
the brake pedal. The pump motor operates when the ABS modulator- control unit is functioning.
The ABS modulator-control unit checks the pump motor operation one time after completing initial
diagnosis during regular diagnosis when the vehicle
is driven over 15 km/h (10 mph).
Brake fluid replacement and air bleeding procedures
are identical to the procedures used on vehicles without
ABS (see page 19-9). The troubleshooting procedures assume that the cause
of the problem is still present, and the ABS indicator is
still on. Following a troubleshooting procedure for a
code that has been cleared but does not reset can result
in incorrect diagnosis.
1. Question the client about the conditions when the problem occurred, and try to reproduce the same
conditions for troubleshooting. Find out when the
ABS indicator came on, such as during activation,
after activation, when the vehicle was traveling at a
certainspeed,etc.Ifnecessary,havetheclient
demonstrate the concern.
2. When the ABS indicator does not come on during the test-drive, check for loose connectors, poor
contact of the terminals, etc. in the circuit indicated
by the DTC before you start troubleshooting.
3. After troubleshooting, or the repairs are done, clear the DTCs, and test-drive the vehicle under the same
conditions that originally set the DTCs. Make sure
the ABS indicator does not come on.
4. Check for DTCs from other systems which are connected via F-CAN. If there are DTCs that are
related to F-CAN, one possible cause was that the
ignition switch was turned to ON (II) with the ABS
modulator-control unit connector disconnected.
Clear the DTCs. Check for fuel and emissions DTC’s
first.
NOTE: Always troubleshoot fuel and emissions
DTC’s first.
The term ‘‘intermittent failure’’ means a system may
have had a failure, but it checks OK now. If you cannot
reproduce the condition, check for loose connectors or
terminal pins related to the circuit that you are
troubleshooting.
08/08/21 15:02:15 61SNR030_190_0050
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Diagnostic Trouble Code (DTC)
Self-diagnosis
Kickback
Pump Motor
Brake Fluid Replacement/Air BleedingHow to Troubleshoot DTCs
Intermittent Failures
19-98
VSA System Components
General Troubleshooting Information (cont’d)
The memory holds all DTCs. However, when the
same DTC is detected more than once, the more
recent DTC is written over the earlier one. Therefore,
when the same problem is detected repeatedly, it is
memorized as a single DTC.
The DTCs are indicated in the order they occur.
The DTCs are memorized in the EEPROM. Therefore, the memorized DTCs cannot be erased by
disconnecting the battery. Do the specified
procedures to clear the DTCs.
Self-diagnosis can be classified into two categories: – Initial diagnosis: Done right after the ignition switch is turned to ON (II) and until the ABS and VSA
indicators go off.
– Regular diagnosis: Done right after the initial diagnosis until the ignition switch is turned to
LOCK (0).
When the system detects a problem, the VSA modulator-control unit shifts to fail-safe mode.
The pump motor operates when the VSA modulator-
control unit is functioning, and the fluid in the reservoir
is forced out to the master cylinder, causing kickback at
the brake pedal. The pump motor operates when the VSA modulator- control unit is functioning.
The VSA modulator-control unit checks the pump motor operation one time after completing initial
diagnosis during regular diagnosis when the vehicle
is driven over 15 km/h (10 mph).
Brake fluid replacement and air bleeding procedures
are identical to the procedures used on vehicles without
the VSA system (see page 19-9). The troubleshooting procedures assume that the cause
of the problem is still present, and the ABS and/or VSA
indicator is still on. Following a troubleshooting
procedure for a code that has been cleared but does not
reset can result in incorrect diagnosis.
1. Question the client about the conditions when the problem occurred, and try to reproduce the same
conditions for troubleshooting. Find out when the
ABS and/or VSA indicator came on, such as during
activation, after activation, when the vehicle was
traveling at a certain speed, etc. If necessary, have
the client demonstrate the concern.
2. When the ABS or VSA indicator does not come on during the test-drive, check for loose connectors,
poor contact of the terminals, etc. in the circuit
indicated by the DTC before you start
troubleshooting.
3. After troubleshooting, or the repairs are done, clear the DTCs, and test-drive the vehicle under the same
conditions that originally set the DTCs. Make sure
the ABS and VSA indicators do not come on.
4. Check for DTCs from other systems which are connected via F-CAN. If there are DTCs that are
related to F-CAN, one possible cause was that the
ignition switch was turned to ON (II) with the VSA
modulator-control unit connector disconnected.
Clear the DTCs. Check for fuel and emissions DTC’s
first.
NOTE: Always troubleshoot fuel and emissions
DTC’s first.
The term ‘‘intermittent failure’’ means a system may
have had a failure, but it checks OK now. If you cannot
reproduce the condition, check for loose connectors or
terminal pins related to the circuit that you are
troubleshooting.
08/08/21 15:04:50 61SNR030_190_0098
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