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

      Tech Tips

      If DTC P1603 is output, clear the DTC Click here.

    3. Crank the engine, 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.

  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. 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 and cover it with a plastic bag.

    2. Observe these precautions when installing the injectors:


      • Never reuse the O-ring.

      • When placing a new O-ring on the injector, 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. B001W8WE13
      Text in Illustration
      *1 Delivery Pipe
      *2 O-Ring
      *3 Injector
      *4 Insulator
      *5 Cylinder Head

      Install the injector to the delivery pipe and cylinder head as shown in the illustration.

      Note

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

    4. B001YMGE06
      Text in Illustration
      *1 Retainer
      *2 No. 2 Fuel Pipe Clamp
      *a Turn
      *b Push

      Observe these precautions when disconnecting the fuel tube connector (for metallic type):

      Note

      Do not forcibly bend or twist the fuel main tube.


      1. Remove the No. 2 fuel pipe clamp.

        Note

        Do not reuse the No. 2 fuel pipe clamp.

      2. Wipe off any dirt on the fuel tube connector.

      3. Hold the fuel tube connector and install SST.

        SST
        09268-21011

      4. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.

      5. Insert SST into the fuel tube connector and hold it. Then push the fuel tube connector toward SST.

      6. Mount the retainer of the fuel tube connector onto the chamfered part of SST.

      7. B001ZA8E54
        Text in Illustration
        *1 O-Ring
        *2 Retainer
        *3 Nylon Tube
        *4 Housing
        *5 Pipe

        Slide SST and the fuel tube connector together towards the fuel tube until they make a "click" sound, and then disconnect the fuel tube.

        Tech Tips

        The structure of a fuel tube connector is as shown in the illustration.

      8. Drain the fuel remaining inside the fuel tube.

      9. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected parts.

    5. Observe these precautions when connecting the fuel tube connector (for metallic type):


      1. Check if there is any damage or foreign objects on the pipe connection area.

      2. B001WPXE03
        Text in Illustration
        *1 Push
        *2 Pull

        Match the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe.

      3. After connecting, check if the pipe and the connector are securely connected by pulling on them.

      4. Install a new No. 2 fuel pipe clamp.

      5. Check that there is no fuel leakage.

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


      1. B001WL9E25
        Text in Illustration
        *A for Fuel Pipe Clamp Type
        *1 Fuel Pipe Clamp

        for Fuel Pipe Clamp Type:

        Remove the fuel pipe clamp from the fuel tube connector.

      2. B001Z9SE19
        Text in Illustration
        *A for Fuel Hose Connector Cover Type
        B001XPG Pull

        for 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. B001W7Y

        Pinch the connector and disconnect the connector and pipe.

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

        Text in Illustration
        B001XPG Pinch
        B001WGT Pull

        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 it with a plastic bag.

    7. 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 connection part of the pipe.

      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.

        Text in Illustration
        B001XPG Push
      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. B001Y50E11
        Text in Illustration
        *A for Fuel Hose Connector Cover Type
        B001XPG Push

        for Fuel Hose Connector Cover Type:

        Attach the lock claw to the connector by pushing down on the cover, as shown in the illustration.

      5. B001WL9E25
        Text in Illustration
        *A for Fuel Pipe Clamp Type
        *1 Fuel Pipe Clamp

        for Fuel Pipe Clamp Type:

        Install the fuel pipe clamp to the connector.

      6. Check that there is no fuel leakage.

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


      1. B001WICE01
        Text in Illustration
        *1 Retainer
        B001XPG Push
        B001WGT Pull
        B001X9H Down

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

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

        Tech Tips

        B001WUB

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

        Text in Illustration
        B001XPG Pull
        B001WGT Push

        Note

        Do not use any tools in this procedure.

      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 it with a plastic bag.

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


      1. B001WA7E04

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

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

        Text in Illustration
        *1 Retainer
        B001XPG Push
        B001WGT Push
      3. B001WPO

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

        Text in Illustration
        B001WGT Pull

      4. Check that there is no fuel leakage.

    10. 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.

    11. 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.

    12. 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. CHECK FOR FUEL LEAK


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