FUEL SYSTEM PRECAUTION

CAUTION:


  • Before working on the fuel system, disconnect the cable from the negative (-) battery terminal.

  • Do not smoke or be near an open flame when working on the fuel system.

  • Keep gasoline away from rubber and leather parts.


  1. IGNITION SWITCH EXPRESSION


    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. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


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

    • After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.


    1. Disconnect the fuel pump ECU connector Click here.

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

      Tech Tips

      If DTC P0230 is output, clear the DTC Click here.

    3. Crank the engine, and then check that the engine does not start.

    4. Loosen the fuel tank cap, and then discharge the pressure in the fuel tank completely.

    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. Connect the fuel pump ECU connector Click here.

  3. FUEL SYSTEM


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


      1. Discharge the fuel system pressure.

      2. Put a container under the connecting part of the pressure line.

      3. Slowly loosen the connection.

      4. Disconnect the connection.

      5. Plug the connection with a rubber plug.

    2. B001YRKE04
      Text in Illustration
      *a OK
      *b NG

      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. B001XBNE01
      Text in Illustration
      *1 O-Ring

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

      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. B001W01E02
        Text in Illustration
        *1 Fuel Pipe Clamp

        Fuel Pipe Clamp Type:

        Remove the fuel pipe clamp from the fuel tube connector.

      2. B001Z9SE18
        Text in Illustration
        *1 Fuel Hose Connector Cover
        B001XPG Pull

        Fuel Hose Connector Cover Type:

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

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

      4. B001W7YE59
        Text in Illustration
        *1 Retainer
        B001XPG Pinch
        B001WGT Pull

        Pinch the connector and disconnect the connector and pipe.

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

        Note

        Do not use any tools in this procedure.

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

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

    5. B001X8T

      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.

        Text in Illustration
        B001XPG Push

      2. 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 spindle oil or gasoline on the tip of the pipe.

      3. B001YAC

        After having finished the connection, try to pull apart the pipe and the connector to confirm that they are securely connected.

        Text in Illustration
        B001XPG Pull

      4. Fuel Hose Connector Cover Type:

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

      5. Fuel Pipe Clamp Type:

        Install the fuel pipe clamp to the connector.

      6. Check that there is no fuel leakage.

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


      1. B001VW9E01
        Text in Illustration
        *1 Retainer
        B001XPG Push
        B001WGT Down
        B001X9H Pull

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

      2. B001WUB

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

        Text in Illustration
        B001XPG Pull
        B001WGT Push

        Note

        Do not use any tools in this procedure.

        Tech Tips

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

      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.

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


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

      2. B001WA7E02
        Text in Illustration
        *1 Retainer
        B001XPG Up
        B001WGT Push

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

      3. B001XQW

        After connecting the pipe and connector, try to pull them apart to confirm that they are securely connected.

        Text in Illustration
        B001XPG Pull

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


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

      2. B001WCNE01
        Text in Illustration
        *1 Retainer
        B001XPG Push
        B001WGT Pull up
        B001X9H Pull

        Pull the retainer up while pinching it on both sides by hand as shown in the illustration, and disconnect the fuel tube connector from the pipe.

        Note

        Do not use any tools.

      3. B001ZI9

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

        Note

        Do not use any tools.

      4. Check for dirt or mud on the pipe seal after disconnecting the fuel tube. Clean it if necessary.

      5. Cover the disconnected fuel tube connector and pipe with a plastic bag.

        Note

        Do not allow the fuel tube connector or pipe to be damaged or contaminated by foreign matter.

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


      1. B001YTZE01
        Text in Illustration
        *1 Retainer
        B001XPG Connect
        B001WGT Push down

        Align the shaft of the fuel tube connector with the shaft of the pipe, push the fuel tube connector in, and push down the retainer.

      2. B001YAS

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

    10. Observe these precautions when handling the nylon tube.

      Note


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

      • Do not kink the nylon tube.

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

  4. CHECK FOR FUEL LEAK


    1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system Click here.