FUEL SYSTEM PRECAUTION


  1. PRECAUTIONS


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

    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 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.

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.


    1. When discharging fuel system pressure by disconnecting the C/OPN relay:


      1. Remove the engine room relay block and junction block assembly cover.

      2. Remove the C/OPN relay.

      3. Set the engine in "inspection mode".

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      4. Start the engine. After the engine has stopped on its own, turn the power 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), P1603 (Engine Stall History), P1604 (Startability Malfunction) or P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

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

      7. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Note

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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      8. Install the C/OPN relay.

      9. Install the engine room relay block and junction block assembly cover.

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


      1. Remove the rear seat cushion assembly.


      2. Remove the rear floor service hole cover.

      3. A01KRHW

        Disconnect the fuel pump connector.

      4. Set the engine in "inspection mode".

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

        Note

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

      6. Crank the engine again and make sure that the engine does not start.

        Tech Tips

        DTC P0171 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) or P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Click here

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

      8. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Note

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

        Click here

      9. Connect the fuel pump connector.

      10. Install the rear floor service hole cover with new butyl tape.

      11. Install the rear seat cushion assembly.


  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 pump tube into a container.

      4. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    2. A01KT5IC08
      *a Retainer
      *b O-ring
      *c Nylon Tube
      *d Fuel Tube Connector
      *e Pipe

      Perform the following procedure when disconnecting a fuel delivery pipe (metallic type):

      Tech Tips

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


      1. A01KR3AC04
        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B

        Remove the No. 2 fuel pipe clamp.

        Note

        Do not reuse the fuel pipe clamp.

      2. Check if there is any damage or foreign matter on the fuel pipe connections.

      3. A01KSVGC01

        Install SST to the fuel tube connector as shown in the illustration.

        SST
        09268-21011
      4. A01KSPTC06
        *a Retainer (4 places)

        Turn SST, align the retainers inside the fuel tube connector with the SST chamfers and insert SST into the fuel tube connector.

      5. Slide SST and the fuel tube connector together towards the fuel tube assembly.

    3. Perform the following procedure when connecting a fuel tube connector (metallic type):


      1. Check if there is any damage or foreign matter on the connecting parts of the fuel lines.

      2. A01KRTMC01
        A01KRLR Push
        A01KR22 Pull

        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.

      3. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

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

      5. Inspect for fuel leaks.

    4. Perform the following procedure when disconnecting a fuel tube connector (quick type A):


      1. A01KSEH

        Release the claw and remove the No. 1 fuel pipe clamp.

      2. Check if there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean if necessary.

      3. A01KTTZC18
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        A01KRLR Pinch
        A01KR22 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.

      5. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel pipe. Clean them if necessary.

      6. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    5. Perform the following procedure when connecting a fuel tube connector (quick type A):


      1. A01KT05C01
        A01KRLR Push
        A01KR22 Pull

        Check if there is any damage or foreign matter on the connecting parts of the fuel pipe.

      2. 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 engine oil to the tip of the fuel pipe and reinsert it.

      3. After connecting the fuel pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      4. Engage the claw and install the No. 1 fuel pipe clamp.

      5. Inspect for fuel leaks.

    6. Perform the following procedure when disconnecting a fuel tube connector (quick type B):


      1. Check if there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean it if necessary.

      2. A01KSBEC04
        *a Retainer

        Disengage the 2 claws of the retainer. Pull down the retainer and disconnect the fuel tube connector from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      3. A01KR6QC01
        A01KRLR Push
        A01KR22 Pull

        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.

      4. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    7. Perform the following procedure when connecting a fuel tube connector (quick type B):


      1. Check if there is any damage or foreign matter on the connecting parts of the fuel lines.

      2. A01KR1XC01
        *a Retainer
        A01KRLR Push
        A01KR22 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 engine oil to the tip of the fuel pipe and reinsert it.

      3. Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      4. Inspect for fuel leaks.

    8. A01KTUOC03
      *a Rubber Hose
      *b O-ring
      *c Retainer
      *d Fuel Pipe
      *e Fuel Tube Connector
      A01KRLR Pull Back
      A01KR22 Pull

      Perform the following procedure when disconnecting a fuel tube connector (quick type C):


      1. Check if there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean it if necessary.

      2. Pull back the retainer of the fuel tube connector as shown in the illustration, and then pull the fuel tube connector to disconnect the fuel tube from the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      3. A01KT0BC01
        A01KRLR Push
        A01KR22 Pull

        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.

      4. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

    9. Perform the following procedure when connecting the fuel tube connector (quick type C):


      1. Check if there is any damage or foreign matter on the connecting parts of the fuel lines.

      2. A01KSV9C03
        A01KRLR 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 engine oil to the tip of the fuel pipe and reinsert it.

      3. A01KRFFC03
        A01KRLR Pull

        After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      4. Inspect for fuel leaks.

    10. A01KTRGC03
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector

      Observe the following precautions when handling the nylon tube:

      Note


      • Do not twist the fuel tube connector part of the nylon tube or fuel tube connector when connecting them.

      • Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.

      • Do not pinch or kink the nylon tubes to prevent fuel leaks.

  4. INJECTOR


    1. A01KR5JC01
      *1 O-ring
      *2 Fuel Delivery Pipe Sub-assembly
      *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 on 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. A01KRD8C03
      *1 Fuel Delivery Pipe Sub-assembly
      *2 O-ring
      *3 Injector Vibration Insulator

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

      Note

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

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. A01KSOHC06
      *a Tube

      Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge assembly. Doing so will cause reassembly of the fuel suction tube with pump and gauge assembly to be impossible as the tube is pressed into the fuel suction plate sub-assembly.

  6. INSPECT FOR FUEL LEAK


    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.

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