FUEL SYSTEM PRECAUTION


  1. PRECAUTIONS


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

      Note

      After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice 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.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • Perform this procedure when the engine coolant temperature is below 60°C (140°F).

    • 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 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. Start the engine. After the engine has stopped on its own, turn the engine 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) may be stored. Clear the DTCs before proceeding to the next step.

        Click here

      5. Remove the fuel tank cap 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 No. 2 relay block cover.

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


      1. Remove the rear seat cushion cover with pad sub-assembly.

        Click here

      2. Remove the rear floor service hole cover.

        Click here

      3. B0045CP

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

      4. Start the engine. After the engine has stopped on its own, turn the engine 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 P0171 (System Too Lean) may be stored. Clear the DTCs before proceeding to the next step.

        Click here

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

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

      9. Install the rear floor service hole cover.

        Click here

      10. Install the rear seat cushion cover with pad 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:


      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. B0046QF

        Disengage the 2 claws and remove the No. 1 fuel pipe clamp. (Clamp Type)

      2. B00488W

        Release the lock of the fuel tube connector cover. (Cover Type)

      3. B00461VC03
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Nylon Tube
        *e Fuel Pipe
        B0046MU Pinch
        B0045SR Pull

        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. B00471TC01
        B0046MU Push

        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. Engage the 2 claws and install the No. 1 fuel pipe clamp. (Clamp Type)

      4. Engage the lock of the fuel tube connector cover. (Cover Type)

      5. Inspect for fuel leaks.

        Click here

    4. Metallic Type:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

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


      1. B0048AL

        Remove the No. 2 fuel pipe clamp.

      2. B00472BN01

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

        SST
        09268-21011
      3. B00455VC10
        *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. B0047PBC24
        *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.

    5. 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. B00464GC03
        B0046MU 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. Install the No. 2 fuel pipe clamp.

      4. Inspect for fuel leaks.

        Click here

  4. INJECTOR


    1. B00466XC01
      *1 Fuel Delivery Pipe
      *2 O-ring
      *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 onto the fuel injector assembly, do not damage the O-ring.

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

        Note

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

    2. B0046MCC03
      *1 Fuel Delivery Pipe
      *2 O-ring
      *3 Injector Vibration Insulator

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

      Note

      Apply gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the fuel injector assembly before installing it.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B0047VMC01
      *a Tube

      Do not disconnect the fuel tube in the locations shown in the illustration.

      Note

      As the fuel tube is press-fit, the seal performance cannot be ensured once the tube has been disconnected.

  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