FUEL SYSTEM PRECAUTION


  1. BEFORE WORKING ON FUEL SYSTEM


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


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

      2. Keep gasoline away from rubber or leather parts.

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

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • Perform the following procedure to prevent fuel from spilling out 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. Connect the intelligent tester to the DLC3.

    2. Remove the relay block cover.

    3. A01NE8TE01
      Text in Illustration
      *1 C/OPN

      Remove the C/OPN relay.

    4. Put the engine in inspection mode Click here.

    5. Start the engine.

    6. After the engine stops, turn the power switch off.

      Tech Tips

      Some DTCs may be stored. Clear the DTCs before proceeding to the next step.

    7. Crank the engine again. Check that the engine does not start.

    8. Remove the fuel tank cap to discharge pressure from the fuel tank.

    9. Install the C/OPN relay.

  3. FUEL LINE


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


      1. Discharge fuel system pressure (Step 2).

      2. Disconnect the fuel pump tube.

      3. Drain the fuel that remains in the fuel pump tube.

      4. A01NGSVE13
        Text in Illustration
        *1 Plastic Bag

        Cover the disconnected fuel pump tube with a plastic bag to prevent damage and contamination.

      5. Put a container under the connectors.

    2. Perform the following procedure when disconnecting a fuel tube connector (Quick Type A):


      1. A01NECYE01
        Text in Illustration
        *1 No. 1 Fuel Pipe Clamp
        *2 No. 2 Fuel Pipe Clamp

        Remove the fuel pipe clamp.

      2. Check whether there is any dirt in the pipe around the connector before disconnecting it and remove the dirt as necessary.

      3. A01NDAYE11

        Disconnect the connector from the pipe by hand.

        Note

        Be sure to disconnect the connector by hand.

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

        Note

        Be sure to disconnect the connector by hand.

      5. Check that there is no dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the surfaces if necessary.

      6. A01NEE6E15
        Text in Illustration
        *1 Plastic Bag

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

    3. A01NCVUE03

      Perform the following procedure when connecting a fuel tube connector (Quick Type A):


      1. Check if there is any damage or foreign objects on the connecting parts of the pipes.

      2. Line up the 2 parts of the pipes to be connected, and push them together until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.

      3. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.

      4. Inspect for fuel leaks Click here.

      5. A01NECYE02
        Text in Illustration
        *1 No. 1 Fuel Pipe Clamp
        *2 No. 2 Fuel Pipe Clamp

        Install the fuel pipe clamp.

    4. A01NDFZ

      Perform the following procedure when disconnecting a fuel tube connector (Quick Type B):


      1. Before disconnecting the connector, clean off any dirt that may be present.

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

        Note

        Be sure to disconnect the connector by hand.

      3. A01NE75E02

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

        Note

        Be sure to disconnect the connector by hand.

      4. Check if there is any dirt or other foreign objects on the sealing surfaces of the disconnected pipes. Clean the sealing surfaces if necessary.

      5. A01ND6BE03
        Text in Illustration
        *1 Plastic Bag

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

    5. A01NHA5

      Perform the following procedure when connecting a fuel tube connector (Quick Type B):


      1. Line up the 2 parts of the pipes to be connected, and fully push the fuel tube connector and pipe together until they are fully seated. Next, push the retainer into the connector until its claws lock. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.

      2. After connecting the pipes, check that the pipe and connector are securely connected by pulling on them.

      3. Inspect for fuel leaks Click here.

    6. A01NHLDE01

      Perform the following procedure when disconnecting a fuel tube connector (Quick Type C):

      Text in Illustration
      *1 Retainer

      1. Check if there is any dirt in the pipe around the connector before disconnecting them and clean the dirt away as necessary.

      2. Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe.

        Note

        Be sure to disconnect the connector by hand.

      3. A01NEGQE05

        If the fuel connector and pipe are stuck, pinch the pipe, then push and pull the fuel tube connector to release and disconnect the fuel tube connector.

      4. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away as necessary.

      5. A01NGWAE01
        Text in Illustration
        *1 Plastic Bag

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

    7. A01NCZ0

      Perform the following procedure when connecting a fuel tube connector (Quick Type C):


      1. Check for damage or foreign objects in the connected part of the pipe.

      2. Align the fuel tube connector with the pipe, then push in the fuel tube connector until the retainer makes a "click" sound.

        Tech Tips

        If they are connected too tightly, apply a light coat of engine oil to the tip of the pipe, then install the fuel tube connector.

      3. A01NHTM

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

      4. Inspect for fuel leaks Click here.

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

      CAUTION:


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

      • Do not bend or twist the nylon tube.

      • 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. A01NGOQE02
      Text in Illustration
      *1 Delivery Pipe
      *2 O-ring
      *3 Injector
      *4 Insulator
      *5 Intake Manifold

      Install the injectors to the delivery pipe and the lower intake manifold as shown in the illustration.

      Note

      Before installing the injector, be sure to apply appropriate lubricant or gasoline where the delivery pipe or intake manifold contacts the injector O-rings.

    2. A01NFJLE01

      Observe the following precautions when removing and installing the fuel injectors:


      1. Never reuse an O-ring.

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

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

        Note

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

  5. INSPECT FOR FUEL LEAK


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