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FUEL SYSTEM PRECAUTION

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  1. PRECAUTION


    1. Before starting on the work for the fuel system inspection and repair, disconnect the cable from the negative (-) battery terminal.

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

    3. Keep gasoline away from rubber or leather parts.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:

    • Take precautions to prevent gasoline from spilling out before removing fuel system parts.

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


    1. Remove the circuit opening relay from the engine room relay block.

    2. Start the engine. After the engine stops, turn the ignition switch off.

      Tip:

      DTC P0171 (system to lean) may be stored.

    3. Check that the engine does not start.

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

    5. 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 battery terminal. Therefore, make sure to read the disconnecting the cable from the 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).

    6. Reinstall the circuit opening relay.

  3. FUEL SYSTEM


    1. When disconnecting a high pressure fuel line, a large amount of gasoline will spill out. Follow these procedures.


      1. Disconnect the fuel pump tube.

      2. Drain any fuel remaining inside the fuel pump tube.

      3. To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag.

      4. Put a container under the connection.

    2. A01DPEKE01

      Observe these precautions when removing and installing the injectors.


      1. Never reuse the O-ring.

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

      3. Coat new O-rings with spindle oil or gasoline before installing. Do not use engine oil, gear oil or brake oil.

    3. A01DM4HE01

      Install the injector to the delivery pipe and lower intake manifold as shown in the illustration.

      Table 1. Text in Illustration
      *1 O-Ring
      Note:

      Before installing the injector, be sure to apply spindle oil or gasoline to the place where the delivery pipe or cylinder head contacts the O-ring of the injector.

    4. Observe these precautions when disconnecting the fuel tube connector (for quick type A).


      1. A01DN4EE01

        Fuel Hose Connector Cover Type:

        Detach the lock claw by lifting up the cover as shown in the illustration.

        Table 2. Text in Illustration
        *1 Fuel Hose Connector Cover

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

      3. A01DQ2QE26

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

        Table 3. Text in Illustration
        *1 Retainer
        A01DQPB Pinch
        A01DMKT Pull
        Note:
        • A01DNJIE01

          Check for foreign matter 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.

        • Do not forcefully bend or twist the nylon tube.

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

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

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

        Table 4. Text in Illustration
        *1 Retainer
        *2 Nylon Tube
        *3 Pipe
        *4 O-Ring
        *5 Fuel Tube Connector

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

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

    5. Observe these precautions when connecting the fuel tube connector (for quick type A).


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

      2. A01DTQYE27

        Align the axis of the connector with the axis of the pipe. Push the 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 pipe.

        Table 5. Text in Illustration
        A01DQPB Push
      3. A01DTQYE28

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

        Table 6. Text in Illustration
        A01DQPB Pull

      4. Fuel Hose Connector Cover Type:

        Attach the lock claws to the connector by pushing down on the cover.

      5. Check for any fuel leaks.

    6. Observe these precautions when disconnecting the fuel tube connector (for quick type B):


      1. Check if there is any dirt or mud on the pipe and around the connector before disconnecting them. Clean if necessary.

      2. Disconnect the parts by hand.

      3. A01DS2X

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

        Table 7. Text in Illustration
        A01DQPB Turn
        A01DMKT Pull
        Note:
        • A01DSG0E02

          Check for foreign matter 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.

        • Do not forcefully bend or twist the nylon tube.

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

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

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

        Table 8. Text in Illustration
        *1 Nylon Tube
        *2 O-Ring
        *3 Retainer
        *4 Pipe

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

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

    7. Observe these precautions when connecting the fuel tube connector (for quick type B):


      1. A01DP71

        Align the axis of the connector with the axis of the pipe and push in the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of new engine oil to the tip of the pipe.

        Table 9. Text in Illustration
        A01DQPB Push
      2. A01DRU8

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

        Table 10. Text in Illustration
        A01DQPB Pull

      3. Check for fuel leaks.

    8. Observe these precautions when disconnecting the fuel tube connector (for quick type C).


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

      2. A01DT0A

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

        Table 11. Text in Illustration
        *1 Retainer
        A01DQPB Push
        A01DMKT Down
        A01DPHJ Pull
        A01DQ1KE02
        Tip:

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

        Table 12. Text in Illustration
        A01DQPB Pull
        A01DMKT Push
        Note:
        • A01DTG4E01

          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.

        • 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 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 tube between your fingers and turn it carefully to free it. Then disconnect the main tube.

        Table 13. Text in Illustration
        *1 Pipe
        *2 Retainer
        *3 Nylon Tube
        *4 Connector
        *5 O-Ring

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

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

    9. Observe these precautions when connecting the fuel tube connector (for quick type C).


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

      2. A01DSN6
        A01DUTSE02

        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.

        Table 14. Text in Illustration
        *1 Retainer
        A01DQPB Up
        A01DMKT Push
        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 the connector, check that the pipe and connector are securely connected by trying to pull them apart.

        Table 15. Text in Illustration
        A01DQPB Pull

    10. Observe these precautions when handling the nylon tube.

      Note:

      • Be careful not to turn the connection part of the nylon tube and the quick connector when connecting them.

      • Do not kink the nylon tube.

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

      • Do not bend the nylon tube as this may cause blockage.

    11. Observe these precautions when disconnecting the fuel tank breather tube connector:


      1. A01DNMAE01

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

        Table 16. Text in Illustration
        *1 Fuel Tank Breather Tube Connector
        *2 Pipe
        A01DQPB Push
        A01DMKT Pinch
        Note:
        • A01DOU1E01

          Remove dirt or foreign objects on the fuel tank breather tube connector before performing this procedure.

        • Do not allow any scratches or foreign objects on the parts when disconnecting them as the fuel tank breather tube connector has the O-ring that seals the pipe.

        • Perform this work by hand. Do not use any tools.

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

        • Protect the connecting part by covering it with a plastic bag after disconnecting the fuel tank breather tube.

        • If the fuel tank breather tube connector and pipe are stuck, push and pull them to release them.

        Table 17. Text in Illustration
        *1 Fuel Tank Breather Tube Connector
        *2 Pipe
        *3 Nylon Tube
        *4 O-Ring

    12. Observe these precautions when connecting the fuel tank breather tube connector:


      1. A01DM40

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

        Table 18. Text in Illustration
        A01DQPB Push
        Note:

        • Check that there are no scratches or foreign objects on the connected part of the fuel tank breather tube connector and pipe before performing this procedure.

        • After connecting the fuel tank breather tube, check that the fuel tank breather tube is securely connected by pulling the fuel tank breather tube connector.

      2. A01DQ5P

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

        Table 19. Text in Illustration
        A01DQPB Pull

      3. Inspect for fuel leaks.

  4. INSPECT FOR FUEL LEAK


    1. Inspect for fuel leaks (Click here).