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. 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 stops, turn the engine switch off.

      Tech Tips

      DTC P0171/0174 (system too lean) may be stored.

    3. Crank the engine again, 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 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.

      • 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.

  2. FUEL SYSTEM


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


      1. Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above.

      2. Disconnect the fuel tube.

      3. Drain any fuel remaining inside the fuel tube.

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

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

    2. B001WASE11
      Text in Illustration
      *1 O-ring
      *2 Fuel Delivery Pipe Sub-assembly
      *a CORRECT
      *b INCORRECT

      Observe these precautions when removing and installing the injectors.

      Note


      • Never reuse the O-ring.

      • When placing a new O-ring on the fuel injector assembly, do not damage it.

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

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

    3. B001W8WE12
      Text in Illustration
      *1 Fuel Delivery Pipe Sub-assembly
      *2 O-ring
      *3 Fuel Injector Assembly
      *4 Insulator
      *5 Cylinder Head Sub-assembly

      Install the fuel injector assembly to the fuel delivery pipe sub-assembly and cylinder head sub-assembly as shown in the illustration.

      Note

      Before installing the fuel injector assembly, apply spindle oil or gasoline on the place where the fuel delivery pipe sub-assembly contacts the O-ring of the fuel injector assembly.

    4. B001VSWE01

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


      1. Fuel Hose Connector Cover Type:

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

        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. B001W7YE60

        Pinch the connector and disconnect the connector and pipe.

        Text in Illustration
        *1 Retainer
        B001XPG Pinch
        B001WGT Pull

        Note


        • B001YVBE01

          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.

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

        Tech Tips

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

      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. Before connecting the connector, check that there is no damage or contamination in the connecting part of the pipe.

      2. B001WKK

        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 to the tip of the pipe.

        Text in Illustration
        B001XPG Push
      3. B001WB4

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

        Text in Illustration
        B001XPG 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 that there is no damage or foreign matter on the part of the pipe that contacts the connector.

      2. B001VW9E01

        Detach the 2 claws of the connector retainer. Push the retainer out and disconnect the connector from the pipe.

        Text in Illustration
        *1 Retainer
        B001XPG Push
        B001WGT Push Out
        B001X9H Pull

        Tech Tips

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

        B001WUB
        Text in Illustration
        B001XPG Pull
        B001WGT Push

        Note


        • B001ZNAE01

          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.

        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 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 if necessary.

      2. B001WA7E02
        B001XQW

        Align the axis of the connector with the axis of the pipe. Push the connector onto the pipe, and then push in the retainer.

        Text in Illustration
        *1 Retainer
        B001XPG Push In
        B001WGT 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 connector, check that the pipe and connector are securely connected by trying to pull them apart.

        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.

  3. FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY

    Note

    Do not disconnect the hoses indicated in the illustration.

    B001YMDE01
    Text in Illustration
    *a for Single Tank Type *b for Double Tank Type

  4. INSPECT FOR FUEL LEAK

    Click here