FUEL SYSTEM PRECAUTION


  1. IGNITION SWITCH EXPRESSIONS


    1. The type of ignition switch used on this model differs according to 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
      Ignition Switch ACC ACC On (ACC)
      Ignition Switch ON ON On (IG)
      Engine Start START Start

  2. FUEL SYSTEM


    1. A005KOQE01
      Text in Illustration
      *1 Plastic Bag

      When disconnecting the fuel line, fuel will splash. So take the following precautions.


      1. Disconnect the fuel tube.

      2. Release the pressure remaining in the fuel tank main tube.

      3. Protect the contact surface by covering it with a plastic bag.

    2. A005JGQE11

      Observe the following precautions when disconnecting the fuel tube connectors (Quick Type A).

      Text in Illustration
      *a Pull

      1. Check that there is no dirt or other foreign matter on the fuel tube connector and pipe before disconnecting them. Clean them if necessary.

      2. Disengage the lock claw by lifting the cover, as shown in the illustration.

      3. A005ITAE34
        Text in Illustration
        *1 Retainer
        *2 O-ring

        Disconnect the fuel tube connector from the pipe by pinching the retainer as shown in the illustration.

        Note

        Do not use any tools.

      4. A005LDJ

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

        Note

        Do not use any tools.

      5. Check the sealing surfaces of the disconnected parts, and clean them if necessary.

      6. A005HY5E06
        Text in Illustration
        *1 Plastic Bag

        Protect the contact surface by covering it with a plastic bag.

        Note

        Do not damage the pipe or fuel tube connector, and prevent entry of foreign objects.

    3. A005L9XE05

      Observe the following precautions when connecting the fuel tube connectors (Quick Type A).

      Text in Illustration
      *a Push
      *b Pull

      1. Check that there is no dirt or other foreign matter on the fuel tube connector and pipe before connecting them. Clean them if necessary.

      2. Line up the pipe and connector and push them together until a "click" sound is heard.

        Tech Tips

        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. A005GOF

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

    4. A005MGQE01

      Observe the following precautions when disconnecting the fuel tube connectors (Quick Type B).

      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Pipe
      *4 O-ring

      Tech Tips

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


      1. Check that there is no dirt or other foreign matter on the fuel tube connector and pipe before disconnecting them. Clean them if necessary.

      2. A005HO8E06
        Text in Illustration
        *1 Retainer

        Pinch the tab on the retainer of the fuel tube connector to disengage the lock claws. Push it down as shown in the illustration.

        Note

        Do not use any tools.

      3. Pull the fuel tank main tube out of the pipe.

      4. A005IC3

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

        Note

        Do not use any tools.

      5. Check for dirt or other foreign matter on the parts to be disconnected and clean them if necessary.

      6. A005KA8E01
        Text in Illustration
        *1 Plastic Bag

        Protect the contact surface by covering it with a plastic bag.

    5. A005H2PE08

      Observe the following precautions when connecting the fuel tube connectors (Quick Type B).

      Text in Illustration
      *1 Retainer

      1. Check that there is no dirt or other foreign matter on the fuel tube connector and pipe before connecting them. Clean them if necessary.

      2. Line up the pipe and connector and push them together until a "click" sound is heard. Lock them by pushing in the retainer.

      3. A005HXA

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

  3. INSPECT FOR FUEL LEAK


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

  4. BLEED AIR FROM FUEL SYSTEM


    • A005KN3E08
      Text in Illustration
      *1 Hand Pump

      (a) Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/sec.

      • The hand pump must be pushed full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If a large amount of air remains inside the fuel system, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    • (b) Start the engine.

      Note


      • If a large amount of air remains inside the fuel system, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.

      Tech Tips


      • When the engine can be started, proceed to the next step.

      • If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to step (a)). Then start the engine.

    • (c) Turn the ignition switch off.

    • (d) Connect the intelligent tester to the DLC3.

    • (e) Turn the ignition switch to ON and turn the tester on.

    • (f) Clear DTCs.

    • (g) Start the engine.

    • A005IT8E09
      Text in Illustration
      *a Active Test Operation

      (h) Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.

    • (i) Maintain the engine speed at 3500 rpm, and then press the "Start" button.

    • (j) Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.

    • (k) Allow the engine to idle for 3 minutes or more after performing the Active Test.

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

      A005KBJE11
      Text in Illustration
      *a Active Test Operation *b 1st time
      *c 2nd time *d 5th time
      *e 10 seconds *f 3 minutes
      *g Time - -

    • (l) Enter the following menus: Powertrain / Engine and ECT / DTC.

    • (m) Read Current DTCs.

      Tech Tips


      • When no DTCs are output, the air bleeding is completed.

      • If any DTCs are output, proceed to the next step.

    • (n) Clear DTCs.

    • (o) Repeat steps (g) to (k).