ТОПЛИВНАЯ СИСТЕМА МЕРЫ ПРЕДОСТОРОЖНОСТИ

CAUTION:

The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.

B0028WJ

  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 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.

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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:


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

    • Even after discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.


    1. Remove the front seat assembly LH.


    2. B0026WR

      Fold back the floor carpet and disconnect the joining connector as shown in the illustration.

      Tech Tips

      This connector has the lines of the fuel pump and rear speed sensor.

    3. Start the engine. After the engine stops, turn the ignition switch off.

      Tech Tips

      DTC P0171/25 (system too lean) may be stored.

    4. Crank the engine again and check that the engine does not start.

    5. Remove the fuel tank cap and let the air out of the fuel tank assembly.

    6. 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.

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

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    7. Connect the joining connector.

    8. Install the front seat assembly LH.


    9. Clear DTCs.

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  3. FUEL SYSTEM


    1. When disconnecting a high 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. B002814C01
      *1 O-Ring
      *2 Fuel Delivery Pipe Sub-assembly
      *a CORRECT
      *b INCORRECT

      Observe these precautions when removing and installing the fuel injector assembly.


      1. Never reuse the O-rings.

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

      3. Coat new O-rings with spindle oil or gasoline before installation. Do not use engine oil, gear oil or brake oil.

    3. B00248JC01
      *1 Fuel Delivery Pipe Sub-assembly
      *2 O-Ring
      *3 Fuel Injector Assembly
      *4 Cylinder Head Sub-assembly
      *5 Injector Vibration Insulator

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

      Note

      Before installing the fuel injector assembly, apply spindle oil or gasoline to the area where the fuel delivery pipe sub-assembly contacts the O-ring of the fuel injector assembly.

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


      1. B00282WC01
        *1 No. 1 Fuel Pipe Clamp
        *2 No. 2 Fuel Pipe Clamp

        for Fuel Pipe Clamp Type:

        Remove the fuel pipe clamp from the fuel tube connector.

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

      3. B0024WEC17
        *a Fuel Hose Connector Cover

        for Fuel Hose Connector Cover Type:

        Detach the lock claw by lifting up the cover as shown in the illustration.

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

      5. B00268AC01
        B0027PX Pinch
        B0027QD Pull

        Pinch the connector and disconnect the connector and pipe.

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

        Note


        • B00267CC03
          *a O-Ring
          *b Connector
          *c Pipe
          *d Retainer
          *e Nylon Tube

          Check for foreign matter 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.

        • Do not forcefully bend or twist the nylon tube.

        • Check for foreign matter on the pipe seal surface. Clean if necessary.

        • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

      6. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.

      7. 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 connected 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.

        Note


        • B00267CC03
          *a O-Ring
          *b Connector
          *c Pipe
          *d Retainer
          *e Nylon Tube

          Before installing the tube connectors to the pipes, check if there is any damage or foreign matter in the connectors.

        • After connecting the connectors and pipes, check if they are securely connected by trying to pull them apart.

      3. B0027K6C01
        B0027PX Pull

        After having finished the connection, try to pull apart the pipe and connector to confirm that they are securely connected.

      4. Install the fuel pipe clamp to the fuel tube connector.

      5. Check that there is no fuel leakage.

      6. for Fuel Hose Connector Cover Type:

        Attach the lock claws to the connector by pushing down on the cover.

      7. for Fuel Pipe Clamp Type:

        Install the fuel pipe clamp to the connector.

      8. Inspect for fuel leaks.

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


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

      2. B0028TWC12
        *a Retainer
        *b Tab
        B0027PX Pull
        B0027QD Pull Out

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

      3. B0027WVC06
        B0027PX Pull
        B0027QD 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 foreign matter 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.

        • Do not forcefully bend or twist the nylon tube.

        • Check for foreign matter on the pipe seal surface. Clean if necessary.

        • Put the pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.

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

      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.

    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. 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. B0027UZC11
        *a Retainer
        B0027PX Insert
        B0027QD Push

        Push down the retainer.

      4. B0026GCC09
        B0027PX Pull

        After having finished the connection, try to pull apart the pipe and connector to confirm that they are securely connected.

      5. Check that there is no fuel leakage.

  4. FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


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

      B002783C01
      *A for Long Wheelbase *B for Short Wheelbase

  5. INSPECT FOR FUEL LEAK


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

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