FUEL SYSTEM PRECAUTION

CAUTION:


  • B004CJ8

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

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

  • B004AP0

    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.

  • B004BVU

    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. BEFORE WORKING ON FUEL SYSTEM


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

      Note

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

      Click here

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

    3. Keep fuel away from rubber or leather parts.

  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. Remove the rear seat cushion assembly.

      Click here

    2. B004CTU

      Remove the No. 2 rear floor service hole cover.

    3. Remove the V-bank cover sub-assembly.

      Click here

    4. Disconnect the fuel pump connector.

    5. B004A02

      Disconnect the 2 connectors.

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

      Click here

    7. Start the engine. After the engine stops, turn the engine switch off.

      Tech Tips

      DTC P008700 (Fuel Rail / System Pressure - Too Low), DTC P017100 (System Too Lean Bank 1), P160300 (Engine Stall History), P160400 (Startability Malfunction) or P160500 (Rough Idling) may be stored. Clear the DTCs.

      Click here

    8. Check that the engine does not start.

      Tech Tips

      If the engine does not stop naturally, perform direct injection by racing the engine to reduce the fuel pressure [Fuel Pressure (High)] and stop the engine.

    9. Remove the fuel tank cap and let the air out of the fuel tank.

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

      Note


      • 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

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

        Click here

    11. Connect the 2 connectors.

    12. Connect the fuel pump connector.

    13. Install the No. 2 rear floor service hole cover.

    14. Install the rear seat cushion assembly.

      Click here

    15. Install the V-bank cover sub-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:

      Note

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


      1. following procedure:

      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.

      5. Put a container under the connection.

    2. Perform the following procedure when disconnecting a fuel tube connector (for quick type A).


      1. B004ASEC04
        *1 Fuel Hose Clamp

        Remove the fuel hose clamp.

      2. Check for dirt or mud on the fuel pipe and around the connector before disconnection. Clean if necessary.

      3. B004BZUC09
        *a Retainer
        B004C4F Pinch
        B004ANI Pull

        If the connector and the fuel pipe are stuck, pinch the connector, push and pull the fuel pipe to disconnect the pipe and pull it out.

        Note


        • B004CLKC28
          *a Retainer
          *b Nylon Tube
          *c Fuel Pipe
          *d O-ring
          *e Fuel Tube Connector

          Check for foreign matter in the fuel pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the fuel pipe and connector.

        • Do not use any tools to separate the fuel pipe and connector.

        • Do not forcefully bend or twist the nylon tube.

        • Check for foreign matter on the fuel pipe seal surface. Clean if necessary.

        • Put the fuel pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

        • If the fuel pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.

      4. Check for dirt or mud on the seal surface of the disconnected fuel pipe. Clean if necessary.

      5. To protect the disconnected fuel pipe and connector from damage and contamination, cover them with a plastic bag.

    3. Perform the following procedure when connecting a fuel tube connector (for quick type A).

      Note

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


      1. Check that there is no damage or contamination in the connected part of the fuel pipe.

      2. B004CKSC01
        B004C4F Push

        Align the axis of the connector with the axis of the fuel pipe. Push the fuel pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil to the tip of the fuel pipe.

      3. B004BJOC01
        B004C4F Pull

        After connecting the fuel pipe and the connector, check that the fuel pipe and connector are securely connected by trying to pull them apart.

      4. Install the fuel hose clamp.

      5. Check for any fuel leaks.

    4. Perform the following procedure when disconnecting a fuel tube connector (for quick type B).

      Note

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


      1. Check that there is no damage or foreign matter on the part of the fuel pipe that contacts the connector.

      2. B004AGRC24
        *a Retainer
        B004C4F Push
        B004ANI Down
        B004BQJ Pull

        Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe.

        Tech Tips

        If the connector and fuel pipe are stuck, pinch the fuel pipe by hand and push and pull the connector to disconnect it.

        B0049UMC02
        B004C4F Pull
        B004ANI Push

        Note


        • B004AA3C27
          *a Retainer
          *b Fuel Pipe
          *c Nylon Tube
          *d Fuel Tube Connector
          *e O-ring

          Check for any dirt and foreign matter contamination in the fuel pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the fuel pipe and connector.

        • Do not use any tools to separate the fuel pipe and connector.

        • Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.

        • Check for any dirt and foreign matter on the fuel pipe seal surface. Clean if necessary.

        • Do not forcibly bend, twist or turn the nylon tube.

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.

        • If the fuel pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.

      3. Check for foreign matter on the seal surface of the disconnected fuel pipe. Clean it if necessary.

      4. To protect the disconnected fuel pipe and connector from damage and foreign matter, cover them with a plastic bag.

    5. Perform the following procedure when connecting a fuel tube connector (for quick type B).


      1. Check for foreign matter on the fuel pipe and around the connector before connecting it. Clean it if necessary.

      2. B004B38C07
        *a Retainer
        *b Claw
        B004C4F Push
        B004ANI Push in
        B004A9YC15
        B004C4F Pull

        Align the axis of the connector with the axis of the fuel pipe. Push the fuel pipe into the connector, and then push up on the retainer.

        Note


        • Before connecting the tube connectors to the fuel pipes, check if there is any damage or foreign matter in the connectors.

        • After connecting the fuel pipe and the connector, check that the fuel pipe and connector are securely connected by trying to pull them apart.

    6. Perform the following procedure when disconnecting a fuel tube connector (for quick type C).


      1. Check that there is no damage or foreign matter on the part of the fuel pipe that contacts the connector.

      2. B004CKPC15
        *a Retainer
        B004C4F Pull
        B004ANI Pull out

        Pull the tabs of the fuel tube connector retainer as shown in the illustration to disconnect the fuel tube connector from the fuel pipe.

        Tech Tips

        If the connector and fuel pipe are stuck, pinch the fuel pipe by hand and push and pull the connector to disconnect it.

        B004BQUC07
        B004C4F Pull
        B004ANI Push

        Note


        • Check for any dirt and foreign matter contamination in the fuel pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the fuel pipe and fuel tube connector.

        • Do not use any tools to separate the fuel pipe and fuel tube connector.

        • Check for any dirt and foreign matter on the fuel pipe seal surface. Clean if necessary.

        • Do not forcibly bend, twist or turn the nylon tube.

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the fuel tube.

        • If the fuel pipe and fuel tube connector are stuck together, pinch the connector between your fingers and turn it carefully to free it. Then disconnect the fuel tube.

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

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

    7. Perform the following procedure when connecting a fuel tube connector (for quick type C).


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

      2. B0049YZC14
        *a Retainer
        B004C4F Push
        B004ANI Push Down

        Line up the fuel pipe and fuel tube connector and push them together until a "click" sound is heard. If the connection is tight, apply a small amount of fresh engine oil to the tip of the fuel pipe.

      3. Push down the retainer.

      4. B004CUCC10
        B004C4F Pull

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

      5. Install the fuel hose clamp.

      6. Attach the claw to close the cover of the fuel hose clamp.

      7. Inspect for fuel leaks.

    8. Perform the following procedure when disconnecting a fuel tube connector (for Quick Type D).

      Note

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


      1. B004C36C01
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Claw
        B004C4F Push
        B004ANI Pull out
        B004BQJ 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. Perform the following procedure when connecting a fuel tube connector (for Quick Type D).

      Note

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


      1. B004A6SC03
        *a Retainer
        *b Claw
        B004C4F Push
        B004ANI 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.

    10. Observe these precautions when disconnecting the fuel tube connector (for quick type E).


      1. B004BGUC04
        *a Retainer
        B004C4F Push
        B004ANI Pull
        B004BQJ Pull Out

        Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe.

      2. B004C97C01
        B004C4F Pull
        B004ANI Push

        If the connector and pipe are stuck together, pinch the pipe by hand and push and pull the connector to disconnect it.

        Note


        • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the pipe and connector.

        • Do not use any tools to separate the pipe and connector.

        • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

        • Do not forcibly bend, twist or turn the nylon tube.

        • Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.

        • If the pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to free it. Then disconnect the main tube.

      3. Check for foreign matter on the seal surface of the disconnected pipe. Clean if necessary.

      4. To protect the disconnected pipe and connector from damage and foreign matter, cover them with a plastic bag.

    11. Observe these precautions when connecting the fuel tube connector (for quick type E).


      1. Check for foreign matter on the pipe and around the connector before connecting them. Clean if necessary.

      2. B004CBUC01
        B004C4F Insert
        B004ANI Push

        Align the axis of the connector with the axis of the pipe. Push the pipe into the connector, and then push up on the retainer.

        Note


        • Before connecting the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

        • After connecting the pipe and connector, check that the pipe and connector are securely connected by trying to pull them apart.

        B004C9ZC01
        B004C4F Pull

      3. Inspect for fuel leaks.

    12. B0049T5C03
      *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.

    13. Metallic Type:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

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


      1. B004BZBC02
        *a Claw

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

        Note

        Do not reuse the No. 2 fuel pipe clamp.

      2. B004AUWN01

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

        SST
        09268-21011
      3. B004B64C10
        *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. B004ASXC22
        *1 Fuel Tube Sub-assembly
        *a Retainer
        *b Nylon Tube
        *c O-ring
        *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 allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the fuel pipe.

        • Do not forcibly bend, twist or turn the nylon tube.

      6. Check if there is any 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.

    14. Metallic Type:

      Perform the following procedure when connecting a fuel tube connector.

      Note

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


      1. B004BIYC03
        B004C4F Push

        Align the fuel tube connector with the fuel pipe, and push the fuel pipe into the fuel tube connector 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 engine oil 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.

  4. FUEL SUCTION TUBE WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. B004A1Q

      Do not disconnect the tube shown in the illustration when disassembling the fuel suction with pump and gauge tube 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 plate.

  5. INSPECT FOR FUEL LEAK

    Click here