Repair Procedure
How to use this service information .
Flammable - Keep Fire Away
NOTICE:
Refer to the Fuel and Emissions Systems Service Precautions before doing the procedure.
USA and Canada Models
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
USA and Canada Models
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
USA and Canada Models
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
Mexico Models
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
Mexico Models
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
Mexico Models
: Torque, N.m (lbf.ft)
: Replace
: Warning/Caution
: Inspection/Adjustment
*: Learning
: SPL Tool
: Required Removal
- A.-
Key Information
Do the following before starting your work.
Remove:
- Left Rear Inner Fender - Refer to: Undercover Area (Type-S) (2024 2025) or Undercover Area (Except Type-S)
Sub-Procedure
■ Removal
- Refer to the figure.
- B.-
Key Information
Do the following before starting your work.
Remove:
- Left Rear Inner Fender - Refer to: Undercover Area (Type-S) (2024 2025) or Undercover Area (Except Type-S)
Sub-Procedure
■ Removal
- Refer to the figure.
- C.-
Sub-Procedure
■ Removal
1. Break the tabs (a).
2. Lift up the hole (b) and release the lock tabs (c).
- D.-
Sub-Procedure
■ Removal
1. Slightly turn the fuel main flap unit/fuel filler flow guide assembly (a) counterclockwise using the capless wrench as shown. (Figure 1)
NOTE:The fuel main flap unit/fuel filler flow guide assembly may move only a small amount. This is normal.
Figure 1
2. Install the capless flapper retainer onto the fuel main flap unit/fuel filler flow guide assembly (b) as shown to keep the flap open. (Figure 2)
Figure 2
3. Insert the capless pick under the lock tab (c) and release the lock by turning the pick counterclockwise. (Figure 3)
NOTE:The lock tab is unlocked when it folds inside the filler neck opening.
Figure 3
4. Turn the fuel main flap unit/fuel filler flow guide assembly (d) clockwise using the capless wrench as shown until it stops, then remove it. (Figure 4)
NOTE:If the lock tab was disengaged properly, the fuel main flap unit/fuel filler flow guide assembly should turn easily. If you feel resistance, confirm that the lock tab was disengaged.
Figure 4
■ Installation
1. Position the fuel main flap unit/fuel filler flow guide assembly (e) onto the filler neck (f) with the top arrow (g) at the 1 o'clock position (h). (Figure 5)
Installation Directions (Figure 5)
Position Direction h 1 o'clock position Figure 5
2. Turn the fuel main flap unit/fuel filler flow guide assembly (i) counterclockwise using the capless wrench until you hear a click. (Figure 6)
NOTE:The top arrow on the fuel main flap unit/fuel filler flow guide assembly should face up.
Figure 6
3. Slightly turn the fuel main flap unit/fuel filler flow guide assembly clockwise to confirm that the lock tab is engaged. The fuel main flap unit/fuel filler flow guide assembly should not turn.
- E.-
- F.-
Sub-Procedure
■ Removal
- Refer to the figure.
- G.-
NOTICE:
Refer to the Fuel Line/Quick-Connect Fitting Precautions - Refer to: Fuel Line/Quick-Connect Fitting Precautions (1.5L Engine) or Fuel Line/Quick-Connect Fitting Precautions (2.0L Engine) (2024 2025) before doing the procedure.
Preconditions
- Fuel Pressure Relieved - Refer to: Fuel Pressure Relieving or Fuel Pressure Test (2.0L Engine) (2024 2025) or Fuel Pressure Test (1.5L Engine)
- Fuel Tank Drained - Refer to: Fuel Tank Removal and Installation (1.5L Engine)
or Fuel Tank Removal and Installation (2.0L Engine) (2024 2025)
or Fuel Tank Draining
NOTICE:
Make sure to drain the fuel until the fuel tank is at or below 3/4.
- 12 Volt Battery Negative Terminal Disconnected
Key Information
Do the following before starting your work.
Remove:
- Rear Seat Area Parts
-
- -
Rear Seat Cushion
- -
Left Rear Seat-Back
- -
Sub-Procedure
NOTICE:
Be careful not to bend or twist the fuel gauge sending unit arm (a) excessively. (Figure 1)
Figure 1
■ Removal
1. Move the fuel connector cover (b), then disconnect the connector (c) and the fuel feed pipe (d). (Figure 2)
Figure 2
2. Cut along the cutting line (e) and remove the fuel pump module cover (f). (Figure 3)
Figure 3
3. Unlock the fuel tank unit cam lock ring (g). (Figure 4)
Figure 4
4. Disconnect the fuel vent tube (h) and the vapor return tube (i) by slightly rotating the fuel tank unit (k) clockwise. (Figure 5)
NOTE:Do not bend the fuel vent tube and the vapor return tube excessively.
Figure 5
5. Hook the lanyard (m) of the ORVR service plug on the hook (n). (Figure 6)
NOTE:Set the ORVR service plug near the fuel tank unit opening.
NOTICE:
- Do not damage any part of the ORVR service plug's surface (o). (Figure 6)
- Damage to the ORVR service plug may cause fuel leaks into the inner fuel vent tube.
- Use the provided protective cap (p) when the ORVR service plug is not in use. (Figure 6)
- If there is damage, discard the ORVR service plug and order a new one.
Figure 6
6. Disconnect the inner fuel vent tube (q) from the fuel tank unit (r) and hold it. (Figure 7)
NOTICE: Do not allow the inner fuel vent tube to drop into the fuel tank.
Figure 7
7. Install the ORVR service plug onto the inner fuel vent tube. (Figure 7)
NOTICE: Make sure the ORVR service plug is fully seated by holding the inner fuel vent tube and gently pulling on the plug's lanyard.
NOTE:The ORVR service plug should not come off.
8. Carefully lower the inner fuel vent tube (s) into the fuel tank (t), making sure the lanyard (u) of the ORVR service plug is free and away from the fuel tank unit (v). (Figure 8)
NOTE:It is OK for the tube to be submerged in the fuel.
Figure 8
■ Installation
1. Grab the lanyard (w) of the ORVR service plug and pull the inner fuel vent tube (x) up until it is close to the fuel tank unit opening. (Figure 9)
NOTE:The ORVR service plug should not come off.
Figure 9
2. Align the tab (y) and the range of the marks (z), and insert the fuel tank unit (aa) partially into the fuel tank. (Figure 9)
3. Move the fuel tank unit aside, allowing space to remove the ORVR service plug from the inner fuel vent tube (ab). (Figure 10)
NOTICE: Do not allow the inner fuel vent tube to fall inside the fuel tank.
NOTE:If fuel enters the inner fuel vent tube, a DTC will set and the fuel tank will need to be replaced.
Figure 10
4. Hold the plugged inner fuel vent tube while reinstalling the fuel tank unit.
5. Remove the ORVR service plug away from the tank opening and connect the inner fuel vent tube to the fuel tank unit.
6. Remove the lanyard (ac) of the ORVR service plug from the hook (ad), then install the provided protective cap (ae). (Figure 11)
Figure 11
7. Align the tab (af) and the range of the marks (ag), and temporarily insert the fuel tank unit cam lock ring (ah). (Figure 12)
Figure 12
8. Connect the fuel vent tube (ai) and vapor return tube (ak) by rotating the fuel tank unit (am) counterclockwise slightly. (Figure 13)
NOTE:Do not bend the fuel vent tube and fuel tank vapor recirculation tube excessively.
Figure 13
9. Make sure the fuel tank unit cam lock ring is seated correctly on the fuel tank unit with all tabs fully engaged, then turn the fuel tank unit cam lock ring (an) clockwise. (Figure 14)
NOTICE:
- Make sure the fuel sender wrench engages fully with the fuel tank unit cam lock ring.
- Securely set the positioning edges (ao) of the fuel tank at the tabs (ap) on the fuel tank unit cam lock ring. (Figure 14)
Figure 14
10. Install the fuel pump module cover (aq) and fix the cutting line (ar) with the pump module cover tape (as). (Figure 15)
Figure 15
11. Connect the connector (at) and the fuel feed pipe (au), then install the fuel connector cover (av). (Figure 16)
Figure 16
After Installation
- 12 Volt Battery Negative Terminal Reconnect
- Fuel Leak Check - Refer to: Fuel Line Inspection (2.0L Engine) (2024 2025) or Fuel Line Inspection (1.5L Engine) (Low Pressure Side)
- H.-
Preconditions
- Fuel Pressure Relieved - Refer to: Fuel Pressure Relieving or Fuel Pressure Test (2.0L Engine) (2024 2025) or Fuel Pressure Test (1.5L Engine)
- Fuel Tank Drained - Refer to: Fuel Tank Removal and Installation (1.5L Engine)
or Fuel Tank Removal and Installation (2.0L Engine) (2024 2025)
or Fuel Tank Draining
NOTICE:
- Make sure to drain the fuel until the fuel tank is at or below 3/4, or drain the fuel until the fuel tank is empty as necessary.
- After draining the fuel tank, temporarily install the fuel tank cam rock ring and the fuel tank unit without connecting the quick-connect fitting and the connector.
- 12 Volt Battery Negative Terminal Disconnected
Key Information
NOTE:For the removal and installation procedure, refer to Fuel Tank Removal and Installation - Refer to: Fuel Tank Removal and Installation (1.5L Engine) or Fuel Tank Removal and Installation (2.0L Engine) (2024 2025) or Fuel Tank Draining and the sub-procedure below.
Sub-Procedure
NOTICE:
Be careful not to interfere with the surrounding parts when removing/installing the pipe.
■ Remove
- To support the fuel tank, use a transmission jack or other support.
Name a Transmission Jack (Commercially Available) ■ Installation
- Installing the fuel tank in the following procedure.
Installation Directions
Position Direction a Front Tightening Procedure
Step Operation Object Detail 1 Temporarily Tighten - 2 Tighten ,
->
3 Temporarily Tighten - 4 Tighten ,
->
After Installation
- 12 Volt Battery Negative Terminal Reconnect
- Fuel Leak Check - Refer to: Fuel Line Inspection (2.0L Engine) (2024 2025) or Fuel Line Inspection (1.5L Engine) (Low Pressure Side)
- I.-
NOTICE:
Refer to the Fuel Line/Quick-Connect Fitting Precautions - Refer to: Fuel Line/Quick-Connect Fitting Precautions (1.5L Engine) or Fuel Line/Quick-Connect Fitting Precautions (2.0L Engine) (2024 2025) before doing the procedure.
Key Information
Do the following before starting your work.
Remove:
- Right Front Floor Undercover - Refer to: Undercover Area (Type-S) (2024 2025) or Undercover Area (Except Type-S)
Sub-Procedure
Figure 1
■ Removal
1. Refer to the figure 1.
Figure 2
2. Refer to the figure 2.
- J.-
Sub-Procedure
■ Installation
- Make sure the hose clamps are properly positioned and tightened - Refer to: Fuel Line Inspection (2.0L Engine) (2024 2025) or Fuel Line Inspection (1.5L Engine) .
- K.-
Sub-Procedure
■ Removal
- Refer to the figure.
NOTICE:
Do not grab for this areas (a).
- Refer to the figure.
- L.-
Sub-Procedure
■ Removal
- Refer to the figure.
- M.-
Sub-Procedure
■ Removal
1. Slightly turn the fuel main flap unit/fuel filler flow guide assembly (a) counterclockwise using the capless wrench as shown. (Figure 1)
NOTE:The fuel main flap unit/fuel filler flow guide assembly may move only a small amount. This is normal.
Figure 1
2. Install the capless flapper retainer onto the fuel main flap unit/fuel filler flow guide assembly (b) as shown to keep the flap open. (Figure 2)
Figure 2
3. Insert the capless pick under the lock tab (c) and release the lock by turning the pick counterclockwise. (Figure 3)
NOTE:The lock tab is unlocked when it folds inside the filler neck opening.
Figure 3
4. Turn the fuel main flap unit/fuel filler flow guide assembly (d) clockwise using the capless wrench as shown until it stops, then remove it. (Figure 4)
NOTE:If the lock tab was disengaged properly, the fuel main flap unit/fuel filler flow guide assembly should turn easily. If you feel resistance, confirm that the lock tab was disengaged.
Figure 4
■ Installation
1. Position the fuel main flap unit/fuel filler flow guide assembly (e) onto the filler neck (f) with the top arrow (g) at the 1 o'clock position (h). (Figure 5)
Installation Directions (Figure 5)
Position Direction h 1 o'clock position Figure 5
2. Turn the fuel main flap unit/fuel filler flow guide assembly (i) counterclockwise using the capless wrench until you hear a click. (Figure 6)
NOTE:The top arrow on the fuel main flap unit/fuel filler flow guide assembly should face up.
Figure 6
3. Slightly turn the fuel main flap unit/fuel filler flow guide assembly clockwise to confirm that the lock tab is engaged. The fuel main flap unit/fuel filler flow guide assembly should not turn.
- N.-
NOTICE:
Refer to the Fuel Line/Quick-Connect Fitting Precautions - Refer to: Fuel Line/Quick-Connect Fitting Precautions (1.5L Engine) or Fuel Line/Quick-Connect Fitting Precautions (2.0L Engine) (2024 2025) before doing the procedure.
Preconditions
- Fuel Pressure Relieved - Refer to: Fuel Pressure Relieving or Fuel Pressure Test (2.0L Engine) (2024 2025) or Fuel Pressure Test (1.5L Engine)
- Fuel Tank Drained - Refer to: Fuel Tank Removal and Installation (1.5L Engine)
or Fuel Tank Removal and Installation (2.0L Engine) (2024 2025)
or Fuel Tank Draining
NOTICE:
Make sure to drain the fuel until the fuel tank is at or below 3/4.
- 12 Volt Battery Negative Terminal Disconnected
Key Information
Do the following before starting your work.
Remove:
- Rear Seat Area Parts
-
- -
Rear Seat Cushion
- -
Left Rear Seat-Back
- -
Figure 1
Sub-Procedure
NOTICE:
Be careful not to bend or twist the fuel gauge sending unit arm (a) excessively. (Figure 1)
Figure 2
■ Removal
1. Move the fuel connector cover (b), then disconnect the connector (c) and the fuel feed pipe (d). (Figure 2)
Figure 3
2. Refer to the figure 3.
Figure 4
■ Installation
1. Align the tab (e) and the range of the marks (f), and temporarily insert the fuel tank unit cam lock ring (g). (Figure 4)
NOTICE: Make sure the fuel tank unit cam lock ring is seated correctly on the fuel tank unit with all tabs fully engaged.
Figure 5
2. Using the fuel sender wrench, turn the fuel tank unit cam lock ring (h) clockwise. (Figure 5)
NOTICE:
- Make sure the fuel sender wrench engages fully with the fuel tank unit cam lock ring.
- Securely set the positioning edges (i) of the fuel tank at the tabs (k) on the fuel tank unit cam lock ring. (Figure 5)
- Make sure the fuel tank unit cam lock ring is seated correctly on the fuel tank unit with all tabs fully engaged.
Figure 6
3. Connect the connector (m) and the fuel feed pipe (n), then install the fuel connector cover (o). (Figure 6)
After Installation
- 12 Volt Battery Negative Terminal Reconnect
- Fuel Leak Check - Refer to: Fuel Line Inspection (2.0L Engine) (2024 2025) or Fuel Line Inspection (1.5L Engine) (Low Pressure Side)
- O.-
Key Information
Do the following before starting your work.
Remove:
- Right Front Floor Undercover - Refer to: Undercover Area (Type-S) (2024 2025) or Undercover Area (Except Type-S)