FUEL SYSTEM PRECAUTION


  1. BEFORE WORKING ON FUEL SYSTEM


    1. When disconnecting a fuel line, fuel will spray. So observe the following precautions:


      1. Do not smoke or work near fire when handling the fuel system.

      2. Keep fuel away from rubber or leather parts.

      3. Perform the Discharge Fuel System Pressure procedure below before disconnecting a fuel line to prevent fuel from spraying.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • Perform the following procedure to prevent fuel from spraying before removing any fuel system parts.

    • Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out.


    1. Remove the rear seat cushion assembly Click here.

    2. Remove the rear floor service hole cover.

    3. B001NRV

      Disconnect the fuel pump connector.

    4. Start the engine.

    5. After the engine has stopped on its own, turn the engine switch off.

    6. Crank the engine again and make sure that the engine does not start.

      Tech Tips

      DTC P0171 (fuel problem) may be stored.

    7. Disconnect the cable from the negative (-) battery terminal.

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

    8. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.

    9. Connect the fuel pump connector.

    10. Install the rear floor service hole cover with new butyl tape.

    11. Install the rear seat cushion assembly Click here.

  3. FUEL LINE


    1. When disconnecting a high pressure fuel line, a large amount of fuel will spray, so perform the following procedure:


      1. Discharge fuel system pressure (Step 2).

      2. Disconnect the fuel tank main tube sub-assembly.

      3. Drain the fuel that remains in the fuel tank main tube sub-assembly.

      4. Cover the disconnected fuel tank main tube sub-assembly with a plastic bag to prevent damage and contamination.

      5. Place a container under the connectors.

    2. B001OG2E02
      Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Retainer
      *3 Fuel Hose Clamp
      *4 Fuel Tube Connector
      *a Turn

      Perform the following procedure when disconnecting the fuel tube sub-assembly.

      Note

      Do not forcibly bend, kink or twist the fuel tube.


      1. Disconnect the fuel tube from the fuel hose clamp.

      2. Remove the No. 2 fuel pipe clamp.

      3. Wipe off any foreign matter on the fuel tube connector.

      4. Hold the fuel tube connector, and then install SST.

        SST
        09268-21011

      5. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.

      6. Insert SST into the fuel tube connector and hold it. Then push the fuel tube connector toward SST.

      7. Mount the retainer of the fuel tube connector onto the chamfered part of SST.

      8. B001NS5E52
        Text in Illustration
        *1 Retainer
        *2 O-ring
        *3 Fuel Tube Sub-assembly
        *4 Fuel Tube Connector
        *5 Fuel Pipe

        Slide SST and the fuel tube connector together until they make a "click" sound, and then disconnect the fuel tube sub-assembly.

      9. Drain the fuel remaining inside the fuel tube sub-assembly.

      10. Cover the fuel tube and fuel pipe with plastic bags to protect the disconnected parts.

    3. B001OM3E03

      Perform the following procedure when connecting the fuel tube.

      Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Fuel Hose Clamp

      1. Check if there is any damage or foreign matter on the fuel pipe connections.

      2. Match the axis of the fuel tube connector with the axis of the fuel pipe, and push it into the fuel tube connector until the fuel tube connector makes a "click" sound. If the connection is tight, apply a small amount of clean engine oil to the tip of the fuel pipe.

      3. B001OJ8

        After finishing the connection, check if the fuel pipe and the fuel tube connector are securely connected by pulling on them.

        Text in Illustration
        B001O8N Push
        B001OAO Pull

      4. Inspect for fuel leaks.

      5. Install a new No. 2 fuel pipe clamp.

      6. Connect the fuel tube to the fuel hose clamp.

    4. Perform the following procedure when disconnecting the fuel tube connector (quick type A):


      1. B001NO2

        Remove the No. 1 fuel pipe clamp.

      2. Check whether there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean it if necessary.

      3. B001NR9E45
        Text in Illustration
        *1 Retainer
        *2 O-ring
        *3 Fuel Tube Connector
        *4 Fuel Pipe
        B001O8N Pinch
        B001OAO Pull Out

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      4. If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release it. Pull the fuel tube connector out of the fuel pipe carefully.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      5. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel pipes. Clean the surfaces if necessary.

      6. Cover the disconnected fuel pipe and fuel tube connector with a plastic bag to prevent damage and contamination.

    5. B001OIH

      Perform the following procedure when connecting a fuel tube connector (quick type A):


      1. Check if there is any damage or foreign matter on the connecting parts of the fuel pipe.

      2. Line up the 2 parts of the fuel lines to be connected, and push them together until the fuel tube connector makes a "click" sound. If the fuel pipe is difficult to push into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

      3. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      4. Inspect for fuel leaks Click here.

      5. Install the No. 1 fuel pipe clamp.

    6. B001O9UE12

      Perform the following procedure when disconnecting a fuel tube connector (quick type B):

      Text in Illustration
      *1 Retainer

      1. Before disconnecting the fuel tube connector, clean off any foreign matter that may be present.

      2. Pinch the tabs of the retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      3. B001OJL

        If the fuel tube connector and fuel pipe are stuck, push and pull on the fuel tube connector while holding the fuel pipe by hand. Pull the 2 fuel lines apart to separate the fuel tube connector.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      4. Check that there is foreign matter on the contact surface of the disconnected fuel pipe. Clean it if necessary.

      5. Cover the disconnected fuel pipe and fuel tube connector with a plastic bag to prevent damage and contamination.

    7. B001NY4

      Perform the following procedure when connecting the fuel tube connector (quick type B):


      1. Line up the 2 parts of the fuel lines to be connected, and fully push the fuel tube connector and fuel pipe together until they are fully seated. Next, push the retainer into the fuel tube connector until its claws lock. If the fuel pipe is difficult to push into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Inspect for fuel leaks Click here.

    8. Observe the following precautions when handling a nylon tube:

      Note


      • Do not twist the fuel tube connector part of the nylon tube or the fuel tube connector when connecting them.

      • Do not remove the EPDM protector on the outside of the nylon tube.

      • Do not pinch or kink the nylon tubes to prevent fuel leakage.

  4. INJECTOR


    1. B001OG1E08
      Text in Illustration
      *1 Fuel Delivery Pipe
      *2 O-ring
      *3 Fuel Injector Assembly
      *4 Injector Vibration Insulator

      Install the fuel injector assembly to the fuel delivery pipe and the cylinder head as shown in the illustration.

      Note

      Before installing the fuel injector assembly, be sure to apply a light coat of fuel or spindle oil where the fuel delivery pipe contacts the O-ring.

    2. B001OOKE08
      Text in Illustration
      *1 O-ring
      *2 Fuel Delivery Pipe
      *a CORRECT
      *b INCORRECT

      Observe the following precautions when removing and installing the fuel injector assemblies:


      1. Do not reuse the O-ring and injector vibration insulator.

      2. When placing a new O-ring on the fuel injector assembly, do not damage the O-ring.

      3. Coat a new O-ring with spindle oil or fuel before installing it.

        Note

        Do not use engine oil, gear oil or brake fluid.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B001O5ME01
      Text in Illustration
      *1 Tube

      Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is welded to the fuel suction plate sub-assembly.

  6. INSPECT FOR FUEL LEAK


    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs Click here.