FUEL SYSTEM PRECAUTION


  1. PRECAUTIONS


    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary battery terminal.

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

    3. Keep gasoline away from rubber or leather parts.

  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 piece of cloth to prevent fuel from spraying or coming out.


    1. Remove the rear seat cushion assembly Click here.

    2. A00442A

      Remove the rear floor service hole cover.

    3. A00445J

      Disconnect the fuel pump connector.

    4. Put the engine in the "inspection mode" Click here.

    5. Start the engine.

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

      Tech Tips

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

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

    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. Connect the fuel pump connector.

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

    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 gasoline will spray out. Perform the following procedure:


      1. Discharge fuel system pressure.

      2. Disconnect the fuel tube.

      3. Drain the fuel remaining inside the fuel pump tube into a container.

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

    2. A0040G2E24

      Perform the following procedure when disconnecting a fuel delivery pipe (metallic type):

      Text in Illustration
      *1 Retainer
      *2 O-ring
      *3 Nylon Tube
      *4 Housing
      *5 Fuel pipe

      Tech Tips

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


      1. Check whether there is any dirt on the fuel pipe around the fuel tube connector before disconnecting it and remove the dirt as necessary.

      2. A0041HOE12
        Text in Illustration
        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B

        Remove the No. 2 fuel pipe clamp.

        Note

        Do not reuse the fuel pipe clamp.

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

      4. A0044AJE01

        Assemble SST to the fuel tube connector as shown in the illustration.

        SST
        09268-21011
      5. A0040Y2E07
        Text in Illustration
        *1 Retainer (4 places)
        *a Turn
        *b Push

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

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

    3. Perform the following procedure when connecting a fuel tube connector (metallic type):


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

      2. A004042E05
        Text in Illustration
        *a Push
        *b Pull

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

      4. A0041HOE09
        Text in Illustration
        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B

        Install a new No. 2 fuel pipe clamp.

      5. Inspect for fuel leaks.

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


      1. A0041AM

        Release the claw and remove the No. 1 fuel pipe clamp.

      2. A0043MHE23
        Text in Illustration
        *1 Fuel Hose Connector Cover

        Disengage the lock claws by raising the fuel hose connector cover as shown in the illustration.

      3. Check whether there is any dirt on the fuel pipe around the fuel tube connector before disconnecting it and remove the dirt as necessary.

      4. Disconnect the fuel tube connector from the fuel pipe by hand.

      5. A0041IJE16
        Text in Illustration
        *1 Retainer
        *2 O-ring
        *a Pinch
        *b Pull Out

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

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

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

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


      1. A0043CRE06
        Text in Illustration
        *a Push
        *b Pull

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

      2. Line up the two parts of the fuel pipes 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 pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      4. A0043MHE24
        Text in Illustration
        *1 Fuel Hose Connector Cover

        Engage the lock claws to the fuel tube connector by pushing down on the fuel hose connector cover.

      5. A0041AM

        Engage the lock claw and install the No. 1 fuel pipe clamp.

      6. Inspect for fuel leaks.

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


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

      2. Pull the tabs of the fuel tube retainer to disengage the 2 claws.

      3. A0043X6E04
        Text in Illustration
        *1 Retainer
        *2 Claw
        *a Pinch
        *b Pull Out

        Pull the retainer up as shown in the illustration.

        Tech Tips

        Be sure to disconnect the fuel tube connector by hand.

      4. A0043KW

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

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

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

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


      1. A0041G8E03
        Text in Illustration
        *1 Retainer
        *2 Claw
        *a Push
        *b Push

        Line up the two parts of the fuel pipes 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 pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

      3. Inspect for fuel leaks.

    8. Perform the following procedure when disconnecting a fuel tube fuel tube connector (quick type C).


      1. Check if there is any dirt like mud on the fuel pipe and around the fuel tube connector before disconnecting them. Clean the dirt away if necessary.

      2. Disconnect them by your hands.

      3. A003ZXME04
        Text in Illustration
        *a Push
        *b Pull

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

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

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

    9. A00411RE04
      Text in Illustration
      *a Push

      Perform the following procedure when connecting a fuel tube connector (quick type C).


      1. 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 it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe.

      2. A0041HZE04
        Text in Illustration
        *a Pull

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

      3. Inspect for fuel leak.

    10. Observe the following precautions when handling a nylon tube.


      1. Do not twist the connection part of the nylon tube and the fuel tube connector when connecting them.

      2. Do not bend, kink, or twist the nylon tube.

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

      4. Do not close the piping by kinking the nylon tube.

  4. INJECTOR


    1. A00433RE02
      Text in Illustration
      *1 O-ring
      *2 Fuel Delivery Pipe
      *a CORRECT
      *b INCORRECT

      Observe the following precautions when removing and installing a fuel injector assembly:


      1. Do not reuse an O-ring and insulator.

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

      3. Coat the new O-ring with grease or gasoline before installing it. Do not use engine oil, gear oil or brake fluid.

    2. A0040DQE01
      Text in Illustration
      *1 Delivery Pipe
      *2 O-ring
      *3 Injector Vibration Insulator

      Install the fuel injector assembly into the fuel delivery pipe and cylinder head as shown in the illustration. Apply grease or gasoline to the contact surfaces of the fuel injector assembly before installing the fuel injector assembly.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. A00402PE01
      Text in Illustration
      *1 Tube

      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 plate.

  6. INSPECT FOR FUEL LEAK


    1. Check that there is no fuel leakage after performing maintenance anywhere on the fuel system Click here.