FUEL SYSTEM PRECAUTION


  1. IGNITION SWITCH EXPRESSIONS


    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. 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 ignition 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.

  3. 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. When discharging fuel system pressure by disconnecting the FUEL PMP relay:


      1. Remove the No. 1 engine room relay block and No. 1 junction block assembly cover.

      2. Remove the FUEL PMP relay.

      3. B003ZP7

        Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.

      4. Start the engine. After the engine has stopped on its own, turn the ignition 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 P008700 (Fuel Rail / System Pressure - Too Low), P017100/P017400 (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.

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

      7. 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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      8. Connect the No. 6 engine wire connector and No. 7 engine wire connector.

      9. Install the FUEL PMP relay.

      10. Install the No. 1 engine room relay block and No. 1 junction block assembly cover.

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


      1. Disconnect the fuel pump connector.

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      2. B003ZP7

        Disconnect the No. 6 engine wire connector and No. 7 engine wire connector.

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

        Note

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

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

        Tech Tips

        DTC P008700 (Fuel Rail / System Pressure - Too Low), P017100/P017400 (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.

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

      6. 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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      7. Connect the No. 6 engine wire connector and No. 7 engine wire connector.

      8. Connect the fuel pump connector.

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  4. 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. B003ZDZC01
        *A Fuel Pipe Camp Type A
        *B Fuel Pipe Camp Type B

        Disengage the 2 claws to remove the No. 2 fuel pipe clamp.

      2. B00401EC01
        *A Fuel Pipe Camp Type A
        *B Fuel Pipe Camp Type B

        Remove the No. 1 fuel pipe clamp from the fuel tube connector.

      3. Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.

      4. B003ZSZC01
        *a Retainer
        *b O-ring
        *c Fuel Tube Connector
        *d Nylon Tube
        *e Fuel Pipe
        B003ZIE Pull out
        B003Z8F Pull off

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

      5. 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


        • 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.

    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. B003ZYJC01
        *a Retainer
        B003ZIE Push
        B003Z8F 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. Install the No. 1 fuel pipe clamp to the fuel tube connector.

      4. Fuel Pipe Clamp Type A:

        Engage the 2 claws to install the No. 2 fuel pipe clamp.

      5. B003ZFPC01
        *a Protrusion
        *b Notch

        Fuel Pipe Clamp Type B:

        Align the protrusions of the No. 2 fuel pipe clamp with the notches of the No. 1 fuel pipe clamp, and engage the 2 claws to install the No. 2 fuel pipe clamp.

      6. 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. B003YY9C02
        *a Retainer
        *b Fuel Pipe
        *c Nylon Tube
        *d Fuel Tube Connector
        *e O-ring
        *f Claw
        B003ZIE Push
        B003Z8F Pull out
        B003ZMU 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.

    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. B004003C02
        *a Retainer
        *b Claw
        B003ZIE Push
        B003Z8F 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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    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. B003ZKBC01
        *a Retainer
        *b Fuel Pipe
        *c Fuel Tube Connector
        *d O-ring
        *e Claw
        B003ZIE Pull
        B003Z8F Pull out
        B003ZMU 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 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.

    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. B003ZUIC01
        *a Retainer
        *b Claw
        B003ZIE Push
        B003Z8F 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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    8. B003Z16C03
      *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.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    Note


    • B003YXVC01
      *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.

    • When replacing the fuel filter, replace it together with 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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