FUEL SYSTEM PRECAUTION


  1. BEFORE WORKING ON FUEL SYSTEM


    1. Before inspecting and repairing the fuel system, 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 negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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    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:


    • Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.

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

    • 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.


    1. Remove the rear seat cushion assembly.

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    2. Remove the rear seat cushion lock hook.

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    3. B003X5MC02
      *a Protective Tape

      Using a clip remover with its tip wrapped with protective tape, remove the rear floor service hole cover and butyl tape.

    4. B003X95

      Disconnect the 2 fuel pump connectors.

    5. B003TWR

      Disconnect the sensor wire connector.

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

      Note

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

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

      Tech Tips

      DTC P017100 (System Too Lean), P160300 (Engine Stall History), P160400 (Startability Malfunction) or P160500 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.


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

    9. Disconnect the cable from the negative (-) battery terminal.

      Note

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

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    10. Connect the sensor wire connector.

    11. Remove any remaining butyl tape from the rear floor service hole cover and vehicle body.

    12. Clean the installation surfaces of the rear floor service hole cover and vehicle body.

    13. Connect the 2 fuel pump connectors.

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

    15. Install the rear seat cushion lock hook.

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    16. Install the rear seat cushion assembly.

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  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. Quick Type A:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. B003UWHC02
        *a Retainer
        *b Fuel Pipe
        *c Nylon Tube
        *d Fuel Tube Connector
        *e O-ring
        *f Claw
        B003WAF Push
        B003U82 Pull out
        B003WLN Pull off

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

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. 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.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

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

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

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

    3. Quick Type A:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. B003W82C02
        *a Retainer
        *b Claw
        B003WAF Push
        B003U82 Push in

        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 gasoline to the tip of the fuel pipe and reinsert it.

      2. 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.

      3. Inspect for fuel leaks.

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    4. Quick Type B:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. B003WNBC03
        *a Fuel Tube Connector
        *b Fuel Pipe
        *c Retainer
        *d O-ring
        B003WAF Pinch
        B003U82 Pull off

        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.

      2. 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.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

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

    5. Quick Type B:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. B003WLAC01
        B003WAF Pull

        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 gasoline to the tip of the fuel pipe and reinsert it.

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

      3. Inspect for fuel leaks.

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    6. Quick Type C:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. B003WJ2C02
        *a Retainer
        B003WAF Pull out
        B003U82 Pull off

        Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      2. B003VVZC01
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Fuel Pipe

        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.

        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

      3. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

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

    7. Quick Type C:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. B003UYHC01
        *a Retainer
        B003WAF Push
        B003U82 Push in

        Align the fuel tube connector with the fuel pipe and push them together. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

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

      3. Inspect for fuel leaks.

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    8. Metallic Type:

      Perform the following procedure when disconnecting a fuel tube connector.

      Note

      Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


      1. B003UIB

        Remove the No. 2 fuel pipe clamp.

        Note

        Do not reuse the No. 2 fuel pipe clamp.

      2. B003X3AN01

        Install SST (fuel hose puller) to the fuel tube connector as shown in the illustration.

        SST
        09268-21011
      3. B003T4XC16
        *a Retainer (4 places)

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

      4. Mount the retainer of the fuel tube connector onto the chamfered part of SST (fuel hose puller).

      5. B003TDNC16
        *a Retainer
        *b O-ring
        *c Nylon Tube
        *d Fuel Tube Connector
        *e Fuel Pipe

        Slide SST (fuel hose puller) and the fuel tube connector together until they make a "click" sound, and then disconnect the fuel tube sub-assembly.

        Note


        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

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

      6. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

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

    9. Metallic Type:

      Perform the following procedure when connecting a fuel tube connector.

      Note

      Check that there is no damage or foreign matter on the connecting parts of the fuel lines.


      1. B003UY6C01
        B003WAF Pull

        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 gasoline to the tip of the fuel pipe and reinsert it.

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

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

      4. Inspect for fuel leaks.

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    10. B003UJSC03
      *a Fuel Tube Connector
      *b Nylon Tube
      *c Ethylene Propylene Diene Monomer (EPDM) Rubber Protector

      Observe the following precautions when handling a nylon tube:

      Note


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

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

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

  4. PORT FUEL INJECTOR ASSEMBLY (for Port Injection)


    1. B003VXNC10
      *1 O-ring
      *2 Fuel Delivery Pipe
      *a Correct
      *b Incorrect

      Observe the following precautions when removing and installing the port fuel injector assemblies:


      1. Do not reuse the O-ring.

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

      3. Apply gasoline or spindle oil to a new O-ring before installing it.

        Note

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

    2. B003V76C05
      *1 Port Fuel Injector Assembly
      *2 Injector Vibration Insulator
      *3 Cylinder Head Sub-assembly

      Install the port fuel injector assembly to the cylinder head sub-assembly as shown in the illustration.

      Note

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


      1. Do not reuse the injector vibration insulator.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Note


    • 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.

    • When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.

    B003X9WC01
    *a Tube

  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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