FUEL SYSTEM PRECAUTION


  1. PRECAUTION


    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) 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 assembly LH Click here.

    2. Remove the rear door scuff plate LH Click here.

    3. Disengage the floor carpet hook, and turn over the front floor carpet.

    4. A003UUS

      Remove the rear floor service hole cover.

    5. Disconnect the fuel pump connector.

    6. Put the engine in inspection mode Click here.

    7. Start the engine.

    8. 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.

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

    10. Disconnect the cable from the negative (-) battery terminal.

    11. Connect the fuel pump connector.

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

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

    2. A003RH3E24

      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 Pipe

      Tech Tips

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


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

      2. A003RIBE08
        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 (Type B).

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

      4. A003UQCE01

        Assemble SST to the connector as shown in the illustration.

        SST
        09268-21011
      5. A003RTOE07
        Text in Illustration
        *1 Retainer (4 places)
        *a Turn
        *b Push

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

      6. Slide SST and the 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 objects on the pipe connections.

      2. A003TE9E02
        Text in Illustration
        *a Push
        *b Pull

        Match the axis of the connector with the axis of the pipe, and push the pipe into the connector 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.

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

      4. A003RIBE09
        Text in Illustration
        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B

        Install the No. 2 fuel pipe clamp (Type A).

      5. Install a new No. 2 fuel pipe clamp (Type B).

      6. Check for fuel leaks.

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


      1. A003SQ1

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

      2. A003UKIE23
        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 that there is no dirt or other foreign objects on the pipe and contact surface before disconnecting them. Clean them if necessary.

      4. Disconnect the connector from the pipe by hand.

      5. A003RV4E16
        Text in Illustration
        *1 Retainer
        *2 O-ring
        *a Pinch
        *b Pull Out

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

      6. Check that there is no dirt or other foreign objects on the contact surface of the disconnected pipe. Clean them away if necessary.

      7. Cover the disconnected pipe and connector with plastic bags to prevent damage and contamination.

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


      1. A003ULGE06
        Text in Illustration
        *a Push
        *b Pull

        Check if there is any damage or foreign objects on the pipe connections.

      2. Line up the two 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. A003UKIE24
        Text in Illustration
        *1 Fuel Hose Connector Cover

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

      5. A003SQ1

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

      6. Check for fuel leaks.

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

      3. A003TERE04
        Text in Illustration
        *1 Retainer
        *2 Claw
        *a Pull
        *b Pull Out

        Pull the retainer up as shown in the illustration.

        Tech Tips

        Be sure to disconnect the connector by hand.

      4. A003U1D

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

      5. If there is any dirt or any other foreign objects on the contact surfaces of the disconnected pipes, clean them as necessary.

      6. Cover the disconnected pipe and connector with plastic bags to prevent damage and contamination.

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


      1. A003RFEE03
        Text in Illustration
        *1 Retainer
        *2 Claw
        *a Push
        *b Push

        Line up the two 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. Check for fuel leaks.

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


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

      2. Disconnect them by your hands.

      3. A003U0IE04
        Text in Illustration
        *a Push
        *b Pull

        When the connector and the pipe are stuck, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time.

      4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe. Clean it away if necessary.

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

    9. A003S8SE04
      Text in Illustration
      *a Push

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


      1. Match the axis of the connector with the axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connection is tight, apply a little amount of new engine oil on the tip of the pipe.

      2. A003T0XE04
        Text in Illustration
        *a Pull

        After having finished the connection, check if the pipe and the connector are securely connected by pulling them.

      3. Check 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 quick 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. A003SZ2E02
      Text in Illustration
      *1 O-ring
      *2 Delivery Pipe
      *a CORRECT
      *b INCORRECT

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


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

      2. When placing a new O-ring onto the injector, 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. A003RXIE01
      Text in Illustration
      *1 Delivery Pipe
      *2 O-ring
      3 Insulator

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

  5. FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE


    1. A003T5DE01
      Text in Illustration
      *1 Tube

      Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube assembly with pump and gauge. Doing so will cause reassembly of the fuel suction tube assembly with pump and gauge 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.