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. For work associated with removal of the C/OPN relay:


      1. Remove the relay block cover.

      2. A019LEUE01
        Text in Illustration
        *1 C/OPN

        Remove the C/OPN relay.

      3. Start the engine.

      4. After the engine stops, turn the engine switch off.

        Tech Tips

        DTC P0171/25 (fuel problem) may be detected.

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

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

      7. Install the C/OPN relay.

    2. Perform the following procedure to disconnect the fuel pump connector:


      1. Remove the rear No. 1 seat assembly (for LH side) Click here.

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

      3. Remove the rear door opening trim weatherstrip LH Click here.

      4. A019MI6

        Remove the rear floor service hole cover.

      5. Disconnect the fuel pump connector.

      6. Start the engine.

      7. After the engine stops, turn the engine switch off.

        Tech Tips

        DTC P0171/25 (fuel problem) may be detected.

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

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

      10. A019MI6

        Reconnect the fuel pump connector.

      11. Install the rear floor service hole cover.

      12. A019OSY

        Install the front floor carpet with the clip.

      13. Install the rear door opening trim weatherstrip LH Click here.

      14. Install the rear door scuff plate LH Click here.

      15. Install the rear No. 1 seat assembly (for LH side) Click here.

  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. A019KZKE13
        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 the fuel tube connector (quick type A):


      1. A019LD1E01
        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. A019NNCE11

        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. A019KGVE15
        Text in Illustration
        *1 Plastic Bag

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

    3. A019M90E03

      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. A019LD1E02
        Text in Illustration
        *1 No. 1 Fuel Pipe Clamp
        *2 No. 2 Fuel Pipe Clamp

        Install the fuel pipe clamp.

    4. A019PBE

      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. A019MCVE02

        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. A019N43E03
        Text in Illustration
        *1 Plastic Bag

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

    5. A019O78

      Perform the following procedure when connecting the 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. 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. A019MRCE02
      Text in Illustration
      *1 Delivery Pipe
      *2 O-ring
      *3 Injector
      *4 Insulator
      *5 Intake Manifold

      Install the injector 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 cylinder head contacts the injector O-rings.

    2. A019LNSE01

      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. FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE


    1. A019NNVE01
      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 are no fuel leaks from the fuel system after doing any maintenance or repairs Click here.