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Special Tools Required
Removal
11-334
Fuel Supply System
Fuel Tank Unit Removal and Installation
A
A
B
C A
07AAA-SNAA100
A
B
Fuel pump module locknut wrench 07AAA-SNAA100 1. Relieve the fuel pressure (see page 11-322).
2. Remove the rear seat cushion (see page 20-131).
3. Remove the rear floor upper cross-member (A).
4. Remove the access panel (A) from the floor.
5. Disconnect the fuel tank unit 4P connector (B).
6. Disconnect the quick-connect fittings (C) from the fuel tank unit. 7. Using the special tool, loosen the locknut (A).
8. Remove the locknut (A) and the fuel tank unit (B).
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Page 664 of 2893

11-336Fuel Supply System
Fuel Tank Unit Removal and Installation (cont’d)
A
B
07AAA-SNAA100 A
120 N·m
(12.2 kgf·m, 88.2 lbf·ft) A
A
4. Install a locknut plate (A) and a new locknut (B).
5. Using the special tool, tighten the new locknut (A) to the specified torque.
NOTE: After tightening, make sure the marks are still aligned.
After installation, check the base gasket, visually or by hand, to make sure it is not pinched. 6. Connect the fuel tank unit 4P connector, then
connect the quick-connect fitting.
7. Reconnect the negative cable to the battery, and turn the ignition switch to ON (II) (but do not
operate the starter motor). The fuel pump will run
for about 2 seconds, and fuel pressure will rise.
Repeat this two or three times, then check that
there is no leakage in the fuel supply system.
8. Install the access panel (A) to the floor.
9. Install the rear floor upper cross-member (A).
10. Install the rear seat cushion (see page 20-131).
11. Install the fuel fill cap.
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11-33711-337
Fuel Pressure Regulator
Replacement Fuel Filter Replacement
A
B
C
D A
D B
C D
B
1. Remove the fuel tank unit (see page 11-334).
2. Remove the bracket (A).
3. Remove the ground ring (B).
4. Remove the fuel pressure regulator (C).
5. Install the parts in the reverse order of removal with new O-rings (D) and a new bracket (A). When
installing the fuel tank unit, align the marks on the
unit and the fuel tank (see page 11-335).
NOTE: Coat the O-rings with clean engine oil; do
not use any other oil.
Do not pinch the O-rings during installation. The fuel filter should be replaced when
ever the fuel
pressure drops below the specified value (see page
11-325), after making sure that the fuel pump and the
fuel pressure regulator are OK.
1. Remove the fuel tank unit (see page 11-334).
2. Remove the fuel filter set (A).
3. Check these items before installing the fuel tank unit:
When connecting the wire harness, make sure the connection is secure and the connectors (B)
are firmly locked into place.
When installing the fuel gauge sending unit (C), make sure the connection is secure and the
connector is firmly locked into place. Be careful
not to bend or twist it excessively.
4. Install the parts in the reverse order of removal with new O-rings (D). When installing the fuel tank
unit, align the marks on the unit and the fuel tank
(see page 11-335).
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Page 699 of 2893
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11-370EGR System
EGR Valve Replacement
A
B
C
D
F
E
22 N·m
(2.2 kgf·m,
16 lbf·ft)
1. Remove the air cleaner (see page 11-345).
2. Relieve the fuel pressure (see page 11-322).
3. Remove the fuel line (A). Disconnect the hose (B).
4. Disconnect CMP sensor A connector (C).
5. Remove the EGR valve 6P connector (D).
6. Remove the EGR valve (E).
7. Install the parts in the reverse order of removal
with a new gasket (F).
08/08/21 14:32:27 61SNR030_110_0370
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Page 703 of 2893
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11-374EVAP System
Component Location Index
EVAPORATIVE EMISSION (EVAP)
CANISTER PURGE VALVE
ENGINE CONTROL MODULE (ECM)/
POWERTRAIN CONTROL MODULE (PCM)
FUEL TANK PRESSURE
(FTP) SENSOR EVAPORATIVE EMISSION (EVAP)
CANISTER VENT SHUT VALVE
FUEL TANK VAPOR CONTROL VALVE
EVAPORATIVE EMISSION
(EVAP) CANISTER FUEL FILL CAP
Replacement, page 11-409
Update, page 11-227
Substitution, page 11-7
Replacement, page 11-228
* : This illustration shows K20Z2 engine.
Replacement, page 11-408 Replacement, page 11-409
Replacement, page 11-407
08/08/21 14:32:32 61SNR030_110_0374
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Page 715 of 2893

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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 ?
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Page 721 of 2893

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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?
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Page 734 of 2893

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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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