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FUEL SYSTEM PRECAUTION

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CAUTION:
B0028WJ

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.


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  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 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.

  3. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:

    • 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 engine room relay block and engine room junction block cover.

    2. A01LFYX

      Remove the fuel pump relay.

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

      Tip:

      DTC P0171 (system too lean) may be stored.

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

    5. Loosen the fuel tank cap assembly, and then discharge the pressure in the fuel tank completely.

    6. Install the fuel pump relay.

    7. Install the engine room relay block and engine room junction block cover.

  4. 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. B0028S3C01
      *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-ring.

      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 installing them. Do not use engine oil, gear oil or brake oil.

    3. B0024OUC01
      *1 Fuel Delivery Pipe Sub-assembly
      *2 O-Ring
      *3 Fuel Injector Assembly
      *4 Intake Manifold
      *5 Fuel 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. B00282WC01
      *1 No. 3 Fuel Tube Clamp
      *2 No. 2 Fuel Pipe Clamp

      Remove the No. 2 fuel pipe clamp and No. 3 fuel tube clamp from the fuel tube connector.

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


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

      2. B00268AC01
        B0068HS Pinch
        B006964 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.

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

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

    6. 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
        B0068HS Pull

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

      4. Check that there is no fuel leakage.

    7. 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
        B0068HS Pull
        B006964 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
        B0068HS Pull
        B006964 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.

    8. 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.

        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. B0027UZC11
        *a Retainer
        B0068HS Insert
        B006964 Push

        Push down the retainer.

      4. B0026GCC09
        B0068HS 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.

    9. Install the No. 2 fuel pipe clamp and No. 3 fuel tube clamp to the fuel tube connector.

  5. FUEL SUCTION WITH PUMP AND GAUGE TUBE ASSEMBLY


    1. A01LB9D

      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.

  6. INSPECT FOR FUEL LEAK


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

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