FUEL SYSTEM PRECAUTION


  1. BEFORE WORKING ON FUEL SYSTEM


    1. Do not work near an open flame.

    2. Keep gasoline away from rubber and leather parts.

    3. Discharge the fuel pressure before disconnecting the fuel line to prevent gasoline from spilling out. Refer to the following procedure.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • The Discharge Fuel System Pressure procedures must be performed before disconnecting any part of the fuel system.

    • After performing the Discharge Fuel System Pressure procedures, pressure will remain in the fuel line. When disconnecting the fuel line, place a cloth or equivalent over fittings to reduce the risk of fuel spray.


    1. Remove the console box sub-assembly.

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    2. B0059UG

      Disconnect the fuel pump and sender gauge connector.

    3. Start the engine. After the engine has stopped, turn the engine switch off.

      Tech Tips

      If DTC P0171 (system too lean) is output, clear the DTC.

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    4. Check that the engine does not start.

    5. 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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    6. Remove the fuel tank cap and discharge the pressure in the fuel tank completely.

    7. Connect the fuel pump and sender gauge connector.

    8. Install the console box sub-assembly.

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  3. FUEL SYSTEM


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


      1. Disconnect the fuel pump tube.

      2. Drain any fuel remaining inside the fuel pump tube.

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

      4. Put a container under the connection.

    2. B0059MYC19
      *a Retainer
      *b O-Ring
      *c Nylon Tube
      *d Fuel Tube Connector
      *e Fuel Pipe

      Observe these precautions when disconnecting a fuel delivery pipe (metallic type).

      Tech Tips

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


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

      2. B0059BRC01
        *A for Type A
        *B for Type B
        *1 EFI Fuel Pipe Clamp
        *a Claw

        Remove the EFI fuel pipe clamp.

        Note

        Always replace the EFI fuel pipe clamp (type B) with a new one, as it is non-reusable.

      3. Find the metallic connector of the fuel tube assembly.

      4. B005BB0N01

        Install SST to the connector as shown in the illustration.

        SST
        09268-21011
      5. B005ARQC19
        *a Retainer

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

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

    3. Observe these precautions when connecting a fuel tube connector (metallic type).


      1. Check if there is any damage or foreign matter on the fuel pipe connection.

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

      3. B0057F8C02
        B0057RX Push
        B0059IK Pull

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

      4. Check that there is no fuel leakage.

      5. for Type A:

        Attach the EFI fuel pipe clamp until a "click" sound is heard.

      6. for Type B:

        Attach a new EFI fuel pipe clamp until a "click" sound is heard.

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


      1. B0058TDC01
        *1 No. 1 Fuel Pipe Clamp

        Remove the No. 1 fuel pipe clamp.

      2. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.

      3. B0059ZKC35
        *a Retainer
        *b O-Ring
        B0057RX Pinch
        B0059IK Pull Out

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

        Note


        • 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.

        • 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 connector between your fingers and turn it carefully to free it. Then disconnect the main tube.

      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. Check that there is no damage or contamination in the connecting part of the pipe.

      2. B005AIEC05
        *a Push
        *b Pull

        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 engine oil to the tip of the pipe.

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

      4. Install the No. 1 fuel pipe clamp.

      5. Inspect for 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. B005BBPC10
        *a Retainer
        B0057RX Pull
        B0059IK Pull out

        Pull the tabs of the fuel tube connector retainer as shown in the illustration to disconnect the fuel tube connector from the pipe.

      3. B0059CIC01
        B0057RX Pull
        B0059IK Push

        If the connector and pipe are stuck together, hold the fuel pipe by hand and push and pull on the connector. Pull the two pipes apart to separate the connector.

        Note


        • 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.

        • 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 connector between your fingers and turn it carefully to free it. Then disconnect the main tube.

      4. Check the sealing surface of the disconnected parts, and clean them if necessary.

      5. To protect the disconnected pipe and connector from damage and contamination, cover them with a plastic bag.

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


      1. Check that there is no damage or contamination in the connected part of the pipe.

      2. B005AQWC09
        *a Retainer
        B0057RX Push
        B0059IK Down

        Line up the pipe and connector and push them together until a "click" sound is heard. If the connection is tight, apply a small amount of fresh engine oil to the tip of the pipe.

      3. Push down the retainer.

      4. B005B65C01
        B0057RX Pull

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

      5. Inspect for fuel leaks.

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


      1. B005AJKC08
        *a Retainer
        B0057RX Push
        B0059IK Pull
        B0057OP Pull Out

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

      2. B0057SEC01
        B0057RX Pull
        B0059IK Push

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

        Note


        • 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.

        • 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 connector between your fingers and turn it carefully to free it. Then disconnect the main tube.

      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.

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


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

      2. B005AL6C08
        *a Retainer
        B0057RX Push
        B0059IK Up

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

        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.

        B005760C01
        B0057RX Pull

      3. Inspect for fuel leaks.

  4. FUEL EVAPORATION TUBE SUB-ASSEMBLY


    1. Perform the following procedure when disconnecting the fuel evaporation tube sub-assembly.


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

      2. B0057F3C02
        *a Fuel Pipe
        *b Retainer
        *c O-Ring
        *d Fuel Tube Connector
        *e Nylon Tube
        B0057RX Pinch

        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.

      3. If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release it. Pull the fuel tube connector out of the fuel pipe carefully.

        Note


        • Check for any dirt and foreign matter contamination in the fuel pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the fuel pipe and fuel tube connector.

        • Do not use any tools to separate the fuel pipe and fuel tube connector.

        • Check for any dirt and foreign matter on the fuel 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 fuel tube.

        • If the fuel pipe and fuel tube connector are stuck together, pinch the connector between your fingers and turn it carefully to free it. Then disconnect the fuel tube.

      4. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel pipes. Clean the surfaces if necessary.

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

    2. Perform the following procedure when connecting the fuel tube connector.


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

      2. Line up the 2 parts of the fuel lines to be connected, and push them together until the fuel tube connector makes a "click" sound. If the fuel pipe is difficult to push 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 lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      4. Inspect for fuel leaks.

  5. FUEL SUCTION TUBE ASSEMBLY WITH PUMP


    1. B0058JG

      Do not disconnect the nylon tube shown in the illustration when disassembling the fuel suction tube assembly with pump. Doing so will cause reassembly of the fuel suction tube assembly with pump to be impossible as the tube is welded to the plate.