FUEL SYSTEM PRECAUTION

  1. PRECAUTIONS

    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 fuel away from rubber or leather parts.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:

    • Perform the following procedure to prevent fuel from spraying 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. When discharging fuel system pressure by disconnecting the C/OPN relay:

      1. Remove the engine room relay block and junction block assembly cover.

      2. Remove the C/OPN relay.

      3. Start the engine. After the engine has stopped on its own, turn the ignition switch off.

        Note:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

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

        Tip:

        DTC P0171 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) and P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

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      5. Remove the fuel tank cap and discharge the pressure from the fuel tank assembly.

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

        Note:

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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      7. Install the C/OPN relay.

      8. Install the engine room relay block and junction block assembly cover.

    2. When discharging fuel system pressure by disconnecting the fuel pump connector:

      1. Remove the rear seat cushion assembly.

      2. A296020

        Disconnect the 2 connectors.

      3. A204394

        Remove the rear floor service hole cover.

      4. Disconnect the fuel pump connector.

      5. Start the engine. After the engine has stopped on its own, turn the ignition switch off.

        Note:

        Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

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

        Tip:

        DTC P0171 (System Too Lean), P1603 (Engine Stall History), P1604 (Startability Malfunction) and P1605 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.

        Click here

      7. Remove the fuel tank cap and discharge the pressure from the fuel tank assembly.

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

        Note:

        When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

        Click hereClick hereClick hereClick hereClick hereClick here

      9. Connect the fuel pump connector.

      10. Install the rear floor service hole cover with new butyl tape.

      11. Connect the 2 connectors.

      12. Install the rear seat cushion assembly.

  3. FUEL LINE

    1. When disconnecting a high-pressure fuel line, a large amount of fuel will spray. Perform the following procedure:

      1. Discharge fuel system pressure.

      2. Disconnect the fuel tube.

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

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

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

      A296018C02

      *A

      Clamp Type

      *B

      Cover Type

      *1

      No. 1 Fuel Pipe Clamp

      -

      -

      *a

      Fuel Tube Connector Cover

      -

      -

      1. Release the claw and remove the No. 1 fuel pipe clamp. (Clamp Type)

        Disengage the lock claws by raising the fuel tube connector cover as shown in the illustration. (Cover Type)

      2. Check that there is no foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean if necessary.

      3. A159424C18

        *a

        Retainer

        *b

        O-ring

        *c

        Fuel Tube Connector
        V100135

        Pinch
        V100136

        Pull

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

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

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      5. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel pipe. Clean if necessary.

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

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

      1. A294326C01
        V100135

        Push
        V100136

        Pull

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

      2. Align the fuel tube connector with the fuel pipe, and push them together 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 and reinsert it.

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

      4. Engage the claw and install the No. 1 fuel pipe clamp. (Clamp Type)

        Engage the lock claws with the fuel tube connector by pushing down on the fuel tube connector cover. (Cover Type)

      5. Inspect for fuel leaks.

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

      1. Check if there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean it if necessary.

      2. A284031C06

        *a

        Retainer

        *b

        Claw
        V100135

        Pull
        V100136

        Pull

        Pull the retainer to disengage the 2 claws and then pull the retainer up as shown in the illustration.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      3. A298118C01
        V100135

        Push
        V100136

        Pull

        If the fuel tube connector and the fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      4. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

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

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

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

      2. A158187C11

        *a

        Retainer

        *b

        Claw
        V100136

        Push
        V100135

        Push In

        Align the fuel tube connector with the fuel pipe, and them 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.

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

      4. Inspect for fuel leaks.

    6. A254815C03

      *a

      Rubber Hose

      *b

      O-ring

      *c

      Retainer

      *d

      Fuel Pipe

      *e

      Fuel Tube Connector
      V100135

      Pull Back
      V100136

      Pull

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

      1. Check if there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean it if necessary.

      2. Pull back the retainer of the fuel tube connector as shown in the illustration, and then pull off the fuel tube connector to disconnect it from the fuel pipe.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      3. A254816C01
        V100135

        Push
        V100136

        Pull

        If the fuel tube connector and the fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note:

        Be sure to disconnect the fuel tube connector by hand.

      4. Check if there is any foreign matter on the sealing surfaces of the disconnected fuel pipes. Clean them if necessary.

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

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

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

      2. A247589C03
        V100135

        Push

        Align the fuel tube connector with the fuel pipe, 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. A247590C03
        V100135

        Pull

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

      4. Inspect for fuel leaks.

    8. A289951C03

      *a

      Fuel Tube Connector

      *b

      Nylon Tube

      *c

      Ethylene Propylene Diene Monomer (EPDM) Rubber Protector

      Observe the following precautions when handling a nylon tube:

      Note:

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

      • Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.

      • Do not pinch or kink the nylon tubes to prevent fuel leaks.

  4. INJECTOR

    1. A296024C01

      *1

      O-ring

      *2

      Fuel Delivery Pipe Sub-assembly

      *a

      Correct

      *b

      Incorrect

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

      1. Do not reuse the O-ring and injector vibration insulator.

      2. When placing a new O-ring onto the fuel injector assembly, 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.

    2. A296025C01

      *1

      Fuel Delivery Pipe Sub-assembly

      *2

      O-ring

      *3

      Injector Vibration Insulator

      Install the fuel injector assembly into the fuel delivery pipe sub-assembly and cylinder head as shown in the illustration.

      Note:

      Apply gasoline or spindle oil to the contact surfaces of the fuel delivery pipe sub-assembly and the fuel injector assembly before installing it.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

    1. A173677C04

      *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 pressed into the fuel suction plate sub-assembly.

  6. INSPECT FOR FUEL LEAK

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

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