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FUEL SYSTEM PRECAUTION

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Info Added 2017-08-02

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  1. BEFORE WORKING ON FUEL SYSTEM


    1. When disconnecting a fuel line, fuel will spray. So observe the following precautions:


      1. Do not smoke or work near fire when handling the fuel system.

      2. Keep fuel away from rubber or leather parts.

      3. Perform the Discharge Fuel System Pressure procedure below before disconnecting a fuel line to prevent fuel from spraying.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:

    • Perform the following procedure to prevent fuel from spraying before removing any fuel system parts.

    • Pressure will still remain in the fuel lines even after performing the following procedure. When disconnecting a fuel line, cover it with a shop rag or a piece of cloth to prevent fuel from spraying or coming out.


    1. Remove the rear seat cushion assembly (Click here).

    2. Remove the rear floor service hole cover.

    3. A0009KH

      Disconnect the fuel pump connector.

    4. Put the engine in inspection mode (Click here).

    5. Start the engine.

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

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

      Tip:

      Some DTCs may be stored. Clear the DTCs before proceeding to the next step (Click here).

    8. Disconnect the cable from the negative (-) auxiliary battery terminal.

      Note:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

    9. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.

    10. Connect the fuel pump connector.

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

    12. Install the rear seat cushion assembly (Click here).

  3. FUEL LINE


    1. When disconnecting a high pressure fuel line, a large amount of fuel will spray, so perform the following procedure:


      1. Discharge fuel system pressure (Step 2).

      2. Disconnect the fuel tank main tube sub-assembly.

      3. Drain the fuel that remains in the fuel tank main tube sub-assembly.

      4. Cover the disconnected fuel tank main tube sub-assembly with a plastic bag to prevent damage and contamination.

      5. Place a container under the connectors.

    2. A0004LFE02

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

      Table 1. Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      *2 Retainer
      *3 Fuel Tube Connector
      A0005GR Turn
      A0009JS Pull
      Note:

      Do not forcibly bend, kink or twist the fuel tube.


      1. Remove the No. 2 fuel pipe clamp.

      2. Wipe off any foreign matter on the fuel tube connector.

      3. Hold the fuel tube connector, and then install SST.

        09268-21011

      4. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.

      5. Insert SST into the fuel tube connector and hold it. Then push the fuel tube connector toward SST.

      6. Mount the retainer of the fuel tube connector onto the chamfered part of SST.

      7. A0007BYE55

        Slide SST into the fuel tube connector until it makes a "click" sound, and then disconnect the fuel tube sub-assembly.

        Table 2. Text in Illustration
        *1 Retainer
        *2 O-ring
        *3 Fuel Tube Sub-assembly
        *4 Fuel Tube Connector
        *5 Fuel Pipe

      8. Drain the fuel remaining inside the fuel tube sub-assembly.

      9. Cover the fuel tube connector and fuel pipe with plastic bags to protect the disconnected parts.

    3. A0006CWE01

      Perform the following procedure when connecting the fuel tube.

      Table 3. Text in Illustration
      *1 No. 2 Fuel Pipe Clamp
      A0005GR Push

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

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

      3. A0006EG

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

        Table 4. Text in Illustration
        A0005GR Push
        A0009JS Pull

      4. Inspect for fuel leaks.

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

      6. Install the fuel tube to the fuel hose clamp.

    4. Perform the following procedure when disconnecting the fuel tube connector (quick type A):


      1. A0005E6

        Remove the No. 1 fuel pipe clamp.

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

      3. A00044YE48

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Table 5. Text in Illustration
        *1 Retainer
        *2 O-ring
        *3 Fuel Tube Connector
        *4 Fuel Pipe
        A0005GR Pinch
        A0009JS Pull Out
        Note:

        Be sure to disconnect the fuel tube connector by hand.

      4. 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:

        Be sure to disconnect the fuel tube connector by hand.

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

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

    5. A00042D

      Perform the following procedure when connecting a fuel tube connector (quick type A):


      1. Check if there is any damage or foreign matter on the connecting part 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 (Click here).

      5. Install the No. 1 fuel pipe clamp.

    6. A00069YE13

      Perform the following procedure when disconnecting a fuel tube connector (quick type B):

      Table 6. Text in Illustration
      *1 Retainer

      1. Before disconnecting the fuel tube connector, clean off any foreign matter that may be present.

      2. Pinch the tabs of the retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      3. A00083G

        If the fuel tube connector and fuel pipe are stuck, push and pull on the fuel tube connector while holding the fuel pipe by hand. Pull the 2 fuel lines apart to separate the fuel tube connector.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      4. Check that there is no foreign matter on the contact surface of the disconnected fuel pipe. Clean it if necessary.

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

    7. A0009OI

      Perform the following procedure when connecting the fuel tube connector (quick type B):


      1. Line up the 2 parts of the fuel lines to be connected, and fully push the fuel tube connector and fuel pipe together until they are fully seated. Next, push the retainer into the fuel tube connector until its claws lock. 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.

      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 (Click here).

    8. Observe the following precautions when handling a nylon tube:

      Note:

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

      • Do not remove the EPDM protector on the outside of the nylon tube.

      • Do not pinch or kink the nylon tubes to prevent fuel leakage.

  4. INJECTOR


    1. A0003GAE05

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

      Table 7. Text in Illustration
      *1 Fuel Delivery Pipe
      *2 O-ring
      *3 Injector Vibration Insulator
      Note:

      Before installing the fuel injector assembly, be sure to apply a light coat of fuel or spindle oil where the fuel delivery pipe contacts the O-ring.

    2. A00052LE06

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

      Table 8. Text in Illustration
      *1 O-ring
      *2 Fuel Delivery Pipe
      *a CORRECT
      *b INCORRECT

      1. Do not reuse the O-ring and injector vibration insulator.

      2. When placing a new O-ring on the fuel injector assembly, do not damage the O-ring.

      3. Coat a new O-ring with spindle oil or fuel before installing it.

        Note:

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

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. A0007PYE01

      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 welded to the fuel suction plate sub-assembly.

      Table 9. Text in Illustration
      *1 Tube

  6. INSPECT FOR FUEL LEAK


    1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs (Click here).