FUEL SYSTEM PRECAUTION

Info Added 2017-10-06

CAUTION:


  • A001RAN

    Never perform work on fuel system components near any possible ignition sources.

  • Vaporized fuel could ignite, resulting in a serious accident.

  • A001PS3

    Do not perform work on fuel system components without first disconnecting the cable from the negative (-) auxiliary battery terminal.

  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

  • A001QVJ

    Because the weight of the fuel tank sub-assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the components could fall down.


  1. PRECAUTION

    Note


    • Keep fuel away from rubber or leather parts.

    • After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery terminal notice before proceeding with work.

      Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.

    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.

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


    1. When discharging fuel system pressure by disconnecting the C/OPN relay:


      1. Remove the No. 2 relay block cover.

      2. Remove the C/OPN relay.

      3. Put the engine in inspection mode (maintenance mode).

        Click here

      4. Start the engine. After the engine has stopped on its own, turn the power switch off.

        Note

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

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

        Tech Tips

        DTC P017100 (System Too Lean), P160400 (Startability Malfunction), P160500 (Rough Idling), P319000 (Poor Engine Power), P319100 (Engine does not Start) or P319300 (Fuel Run Out) may be stored. Clear the DTCs before proceeding to the next step.


      6. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.

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

        Click here

        Note

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

        Click here

      8. Install the C/OPN relay.

      9. Install the No. 2 relay block cover.

    2. When discharging fuel system pressure by disconnecting the fuel pump connector:


      1. Disconnect the rear center seat outer belt assembly.

        Click here

      2. Remove the bench type rear seat cushion assembly.

        Click here

      3. Remove the rear seat cushion lock hook.

        Click here

      4. Remove the No. 8 wiring harness protector from the rear floor service hole cover.

      5. A001PZGC02
        *a Protective Tape

        Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

      6. A001PT5

        Disconnect the fuel suction tube with pump and gauge assembly connector.

      7. Put the engine in inspection mode (maintenance mode).

        Click here

      8. Start the engine. After the engine has stopped on its own, turn the power switch off.

        Note

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

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

        Tech Tips

        DTC P017100 (System Too Lean), P160400 (Startability Malfunction), P160500 (Rough Idling), P319000 (Poor Engine Power), P319100 (Engine does not Start) or P319300 (Fuel Run Out) may be stored. Clear the DTCs before proceeding to the next step.


      10. Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.

      11. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Click here

        Note

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

        Click here

      12. Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.

      13. Clean the installation surfaces of the rear floor service hole cover and vehicle body.

      14. Connect the fuel suction tube with pump and gauge assembly connector.

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

      16. Install a new No. 8 wiring harness protector to the rear floor service hole cover.

      17. Install the rear seat cushion lock hook.

        Click here

      18. Install the bench type rear seat cushion assembly.

        Click here

      19. Connect the rear center seat outer belt assembly.

        Click here

  3. FUEL LINE


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


      1. Discharge fuel system pressure.

      2. Disconnect the fuel tube.

      3. Drain the fuel remaining inside the fuel tube into a container.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    2. Quick Type A:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. A001QW0C02
        *a Open
        B0048S8 Pull

        Open the cover of the fuel pipe clamp and remove the fuel pipe clamp from the fuel tube connector.

      2. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.

      3. A001OCNC01
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe
        *e Nylon Tube
        B0048I2 Pinch
        B0048S8 Pull off

        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 fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

        • Do not bend, twist, pinch or kink the nylon tube.

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

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

    3. Quick Type A:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. A001OGEC01
        B0048I2 Pull

        Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline 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. Install the fuel pipe clamp to the fuel tube connector and close the cover of the fuel pipe clamp.

      4. Inspect for fuel leaks.

        Click here

    4. Quick Type B:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. A001QTPC03
        *a Retainer
        B0048I2 Pull out
        B0048S8 Pull off

        Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

      2. A001O5YC03
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe

        If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note

        Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    5. Quick Type B:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. A001POVC03
        *a Retainer
        B0048I2 Push
        B0048S8 Push in

        Align the fuel tube connector with the fuel pipe and push them together. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

      2. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Inspect for fuel leaks.

        Click here

    6. Quick Type C:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. A001QKFC08
        *a Retainer
        *b Fuel Pipe
        *c Nylon Tube
        *d Fuel Tube Connector
        *e O-ring
        *f Claw
        B0048I2 Push
        B0048S8 Pull out
        A001RGS Pull off

        Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

        • Do not bend, twist, pinch or kink the nylon tube.

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    7. Quick Type C:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. A001R9OC05
        *a Retainer
        *b Claw
        B0048I2 Push
        B0048S8 Push in

        Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

      2. Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Inspect for fuel leaks.

        Click here

    8. Quick Type D:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. A001OK6C01
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Claw
        B0048I2 Push
        B0048S8 Pull out
        A001RGS Pull off

        Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    9. Quick Type D:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. A001OYXC05
        *a Retainer
        *b Claw
        B0048I2 Push
        B0048S8 Push in

        Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

      2. Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Inspect for fuel leaks.

        Click here

    10. Quick Type E:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. A001OLGC02
        *a Fuel Tube Connector
        *b Fuel Pipe
        *c Retainer
        *d O-ring
        B0048I2 Pull out
        B0048S8 Pull off

        Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

      2. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note

        Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    11. Quick Type E:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. A001P8KC02
        *a Retainer
        B0048I2 Push
        B0048S8 Push in

        Align the fuel tube connector with the fuel pipe and push them together. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

      2. Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Inspect for fuel leaks.

        Click here

    12. A001RKFC09
      *1 Fuel Tank Breather Tube Connector
      *2 Pipe
      *3 O-ring
      *a Nylon Tube

      Quick Type F:

      Observe these precautions when disconnecting the charcoal canister outlet tube connector:


      1. Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.

      2. A001OIXC08
        *1 Fuel Tank Breather Tube Connector
        *a Pipe
        B0048I2 Push
        B0048S8 Pinch

        Pinch the retainer and pull out the fuel tank breather tube connector with the fuel tank breather tube connector pushed to the pipe side to disconnect the fuel tank breather tube from the pipe.

        Note

        Do not use any tools.

      3. If the connector and pipe are stuck, pinch the retainer with your hand, and then push and pull the connector to disconnect them.

        Note

        Do not use any tools.

      4. Check the sealing surfaces of the disconnected parts, and clean them if necessary.

      5. Protect the contact surface by covering it with a plastic bag.

        Note

        Do not damage the pipe or fuel tube connector, and prevent entry of foreign objects.

    13. A001OH8C07
      B0048I2 Push

      Quick Type F:

      Observe these precautions when connecting the charcoal canister outlet tube connector:


      1. Check that there are no scratches or foreign objects on the connecting part.

      2. Align the fuel tank breather tube connector with the pipe, then push in the fuel tank breather tube connector until the retainer makes a "click" sound to install the fuel tank breather tube to the pipe.

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

      4. A001R7XC07
        B0048I2 Push

        Inspect for fuel leak.

        Click here

    14. Metallic Type:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. A001QFH

        Remove the No. 1 fuel pipe clamp.

      2. A001PABN03

        Install SST (fuel hose puller) to the fuel tube connector as shown in the illustration.

        SST
        09268-21011
      3. A001S5YC07
        *a Retainer (4 places)

        Turn SST (fuel hose puller), align the retainers inside the fuel tube connector with the SST (fuel hose puller) chamfers and insert SST (fuel hose puller) into the fuel tube connector.

      4. Mount the retainer of the fuel tube connector onto the chamfered part of SST (fuel hose puller).

      5. A001PK8C16
        *a Retainer
        *b O-ring
        *c Nylon Tube
        *d Fuel Tube Connector
        *e Fuel Pipe

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

        Note


        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

        • Do not bend, twist, pinch or kink the nylon tube.

      6. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      7. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    15. Metallic Type:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. A001ROEC01
        B0048I2 Pull

        Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline 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. Install a new No. 1 fuel pipe clamp.

      4. Inspect for fuel leaks.

        Click here

    16. A001QAWC03
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector

      Observe the following precautions when handling a nylon tube:

      Note


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

      • Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.

      • Do not bend, twist, pinch or kink the nylon tube.

  4. FUEL INJECTOR ASSEMBLY


    1. A001O7GC12
      *1 O-ring
      *2 Fuel Delivery Pipe Sub-assembly
      *a Correct
      *b Incorrect

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


      1. Do not reuse the O-ring.

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

      3. Apply gasoline or spindle oil to a new O-ring before installing it.

        Note

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

    2. A001PN3C14
      *1 Fuel Delivery Pipe Sub-assembly
      *2 O-ring
      *3 Fuel Injector Assembly
      *4 Injector Vibration Insulator

      Install the fuel injector assembly to the cylinder head sub-assembly as shown in the illustration.


      1. Do not reuse the injector vibration insulator.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Note

    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 pressed into the plate sub-assembly.

    A001NZ1C01
    *a Tube

  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