Aura, Outlook 2007

Removal & Installation

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NOTE
Clean the fuel and Evaporative Emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.

  1. Relieve the fuel system pressure.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Disconnect the fuel tank fuel pump module wiring harness electrical connector from body wiring harness electrical connector.
  8.  
  9. Remove the body wiring harness electrical connector clip from the EVAP canister.
  10.  
  11. Disconnect the body wiring harness electrical connector from the rear Antilock Brake System (ABS) wiring harness electrical connector.
  12.  
  13. Remove the rear ABS wiring harness electrical connector clip from the EVAP canister.
  14.  
  15. Disconnect the fuel tank fuel feed pipe quick connect fitting from the chassis fuel feed pipe.
  16.  
  17. Disconnect the fuel tank EVAP pipe quick connect fitting from the chassis EVAP pipe.
  18.  
  19. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
  20.  
  21. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting from the fuel tank vent pipe.
  22.  
  23. Place a jackstand under the muffler assembly.
  24.  
  25. With the aid of an assistant, separate the muffler insulators from the underbody hangers.
  26.  
  27. Slowly lower the muffler assembly allowing it to rest on the jackstand. If this is not possible, remove the muffler assembly.

    Click image to see an enlarged view

    Fig. Fuel tank mounting-Aura

  28.  
  29. Have assistants support either side of the fuel tank.
  30.  
  31. Place a suitable adjustable jack under the fuel tank, and have the assistants rest the fuel tank on the adjustable jack.
  32.  
  33. Remove fuel tank strap bolts and straps.
  34.  
  35. If applicable, in order to clear the muffler assembly, slowly lower the right side of the fuel tank.
  36.  
  37. Once the tank is clear of the right frame rail, lower the fuel tank down and remove forward toward the right side of the vehicle.
  38.  

To install:

  1. Have assistants support either side of the fuel tank.
  2.  
  3. If applicable, begin to install the right side of the fuel tank over the muffler assembly. If applicable, raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed, EVAP line wiring harness over the muffler assembly.
  4.  
  5. If applicable and the muffler assembly was removed, have assistants raise the fuel tank into position.
  6.  
  7. Install fuel tank straps and bolts. Tighten the bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Raise the muffler assembly into position if applicable, otherwise install the muffler assembly.
  10.  
  11. With the aid of an assistant, install the muffler insulators to the underbody hangers.
  12.  
  13. Remove the jackstand from under the muffler assembly.
  14.  
  15. Install the fuel fill pipe hose to the fuel tank.
  16.  
  17. Connect the fuel tank fill EVAP emission pipe quick connect fitting to the fuel tank vent pipe.
  18.  
  19. Tighten the fuel fill pipe hose clamp at the fuel tank.
  20.  
  21. Remove the caps from the fuel and EVAP pipes.
  22.  
  23. Connect the fuel tank EVAP pipe quick connect fitting to the chassis EVAP pipe.
  24.  
  25. Connect the fuel tank fuel feed pipe quick connect fitting to the chassis fuel feed pipe.
  26.  
  27. Install the rear ABS wiring harness electrical connector clip to the EVAP canister.
  28.  
  29. Connect the body wiring harness electrical connector to the rear ABS wiring harness electrical connector.
  30.  
  31. Install the body wiring harness electrical connector clip to the underbody.
  32.  
  33. Connect the fuel tank fuel pump module wiring harness electrical connector to the body wiring harness electrical connector.
  34.  
  35. Lower the vehicle.
  36.  
  37. Refill the fuel tank.
  38.  
  39. Tighten the fuel fill cap.
  40.  
  41. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds
    4.  
    5. Turn ON the ignition
    6.  
    7. Inspect for fuel leaks.
    8.  

  42.  


CAUTION
Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.


CAUTION
Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the fuel tank.
    CAUTION
    Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.


    NOTE
    Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

  4.  
  5. Disconnect the fuel pump fuel feed line quick connect fitting from the chassis fuel line.
  6.  
  7. Disconnect the fuel tank Evaporative Emission (EVAP) canister vent front pipe quick connect fitting from the chassis EVAP line.
  8.  
  9. Disconnect the vent hose from the left rear of the fuel tank.
  10.  
  11. Disconnect the fuel sender wiring harness electrical connector from the body wiring harness electrical connector.
  12.  
  13. Remove the fuel sender wiring harness clip from the underbody side rail extension.
  14.  
  15. Remove the left underbody side rail.
  16.  
  17. Support the fuel tank with a suitable adjustable jack.
  18.  
  19. Remove the fuel tank strap bolts. Allow the fuel tank straps to hang.
    NOTE
    Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.



    Click image to see an enlarged view

    Fig. Location of the fuel tank straps (1)-Outlook

  20.  
  21. Push up on the rear of the strap slightly and rotate the strap towards the rear of the vehicle, in order the remove the fuel tank straps.
  22.  
  23. Using the adjustable jack and the aid of an assistant, lower the fuel tank from the underbody of the vehicle.
  24.  
  25. With the aid of the assistant, remove the fuel tank from the adjustable jack, and place on a flat work surface.
  26.  

To install:

  1. With the aid of an assistant, remove the fuel tank from the work surface and place on the adjustable jack.
  2.  
  3. With the aid of the assistant, raise the fuel tank into position under the vehicle.
  4.  
  5. Install the fuel tank straps and tighten the bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Remove the adjustable jack from under the fuel tank.
  8.  
  9. Install the left underbody side rail.
  10.  
  11. Connect the fuel sender wiring harness electrical connector to the body wiring harness electrical connector.
  12.  
  13. Install the fuel sender wiring harness clip to the underbody side rail extension.
  14.  
  15. Connect the vent hose to the left rear of the fuel tank.
  16.  
  17. Connect the fuel tank EVAP canister vent front pipe quick connect fitting to the chassis EVAP line.
  18.  
  19. Connect the fuel pump fuel feed line quick connect fitting to the chassis fuel line.
    NOTE
    Ensure that the notch in the fill hose aligns with the tab on the fuel tank.

  20.  
  21. Position and install the fuel tank fill pipe to the fuel tank.
  22.  
  23. Connect the EVAP canister vent rear pipe quick connect fitting to the recirculation line on the fuel fill pipe.
  24.  
  25. Tighten the fuel tank fill hose clamp at the fuel tank to 29 in. lbs. (3.3 Nm).
  26.  
  27. Lower the vehicle.
  28.  
  29. Refill the fuel tank.
  30.  
  31. Tighten the fuel fill cap.
  32.  
  33. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds
    4.  
    5. Turn ON the ignition
    6.  
    7. Inspect for fuel leaks.
    8.  

  34.  
  35. Install the fuel injector sight shield.
  36.  

 
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