FUEL SYSTEM PRECAUTION

CAUTION:


  • B006ZQO

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

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

  • B006XC9

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

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

  • B0070IK

    The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.


  1. IGNITION SWITCH EXPRESSIONS


    1. The type of ignition switch used on this model differs depending on the specifications of the vehicle. The expressions listed in the table below are used in this section.

      Expression Ignition Switch (Position) Engine Switch (Condition)
      Ignition Switch off LOCK Off (Lock)
      Ignition Switch ACC ACC On (ACC)
      Ignition Switch ON ON On (IG)
      Engine Start START On (Start)

  2. BEFORE WORKING ON FUEL SYSTEM


    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.

      Note

      After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

      Click here

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

    3. Keep fuel away from rubber or leather parts.

  3. 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 engine room relay block and junction block assembly cover.

      2. Remove the C/OPN relay.

      3. Start the engine. After the engine has stopped on its own, turn the ignition switch off.

        Note

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

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

        Tech Tips

        DTC P0171 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) and P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Click here

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

      6. 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

      7. Install the C/OPN relay.

      8. Install the engine room relay block and junction block assembly cover.

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


      1. Disconnect the rear center seat outer belt assembly.


      2. Remove the rear seat cushion assembly.


      3. Remove the rear seat cushion lock hook.


      4. B006Y9WC01
        *a Protective Tape

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

      5. B006YGP

        Disconnect the fuel pump connector.

      6. Start the engine. After the engine has stopped on its own, turn the ignition switch off.

        Note

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

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

        Tech Tips

        DTC P0171 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) and P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Click here

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

      9. 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

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

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

      12. Connect the fuel pump connector.

      13. B006YUXC01
        *a Butyl Tape Adhesion Area

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

        Note

        Securely install the rear floor service hole cover.

      14. Install the rear seat cushion lock hook.


      15. Install the rear seat cushion assembly.


      16. Connect the rear center seat outer belt assembly.


  4. 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 pump 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. B006ZOBC01
        B006Z38 Open
        B006ZY0 Pull

        Open the cover of the No. 1 fuel pipe clamp and remove the No. 1 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. B006YNVC01
        *a Retainer
        B006Z38 Retainer Holding Position
        B006ZY0 Pull up

        While holding the retainer at the positions shown in the illustration, pull up the retainer to disengage the lock claws.

      4. B006XRSC01
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Nylon Tube
        *e Fuel Pipe
        B006Z38 Retainer Holding Position
        B006ZY0 Pull out
        B006YM5 Pull off

        Pull up the retainer while holding it at the positions shown in the illustration and pull off the fuel tube connector.

      5. 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).

        • 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.

    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. B006YKAC01
        *a Retainer
        B006Z38 Push
        B006ZY0 Push in

        Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to secure the connection.

        Note

        Confirm that the retainer makes a "click" sound when pushed.

        Tech Tips

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      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 No. 1 fuel pipe clamp to the fuel tube connector and close the cover of the No. 1 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. B006XNEC01
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Claw
        B006Z38 Pull
        B006ZY0 Pull out
        B006YM5 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.

    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. B006XO8C01
        *a Retainer
        *b Claw
        B006Z38 Push
        B006ZY0 Push in

        Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to engage the 2 claws.

        Note

        Confirm that the retainer makes a "click" sound when pushed.

        Tech Tips

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      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

    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. B00719GC02
        *a Retainer
        *b Fuel Pipe
        *c Nylon Tube
        *d Fuel Tube Connector
        *e O-ring
        *f Claw
        B006Z38 Push
        B006ZY0 Pull out
        B006YM5 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. B0070OSC02
        *a Retainer
        *b Claw
        B006Z38 Push
        B006ZY0 Push in

        Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to engage the 2 claws.

        Note

        Confirm that the retainer makes a "click" sound when pushed.

        Tech Tips

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

      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. 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. B0070DFC01
        *a Claw

        Disengage the 2 claws to remove the No. 2 fuel pipe clamp.

      2. B0070X0N03

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

        SST
        09268-21011
      3. B0070Q1C07
        *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. B007038C16
        *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 connector.

        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.

    9. 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. B006Y1JC01
        B006Z38 Pull

        Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound.

        Tech Tips

        If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

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

      3. Engage the 2 claws to install a new No. 2 fuel pipe clamp.

      4. Inspect for fuel leaks.

        Click here

    10. B006XVAC03
      *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.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Note


    • B006XIZC01
      *a 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 pressed into the fuel suction plate sub-assembly.

    • When replacing the fuel filter, replace it together with 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