BEFORE WORKING ON FUEL SYSTEM
When disconnecting a fuel line, fuel will spray. So observe the following precautions:
Do not smoke or work near fire when handling the fuel system.
Keep fuel away from rubber or leather parts.
Perform the Discharge Fuel System Pressure procedure below before disconnecting a fuel line to prevent fuel from spraying.
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 shop rag or a piece of cloth to prevent fuel from spraying or coming out.
Remove the rear seat cushion assembly Click here.
Remove the rear floor service hole cover.
Disconnect the fuel pump connector.
Start the engine.
After the engine has stopped on its own, turn the engine switch off.
Crank the engine again and make sure that the engine does not start.
Tech Tips
DTC P0171 (fuel problem) may be stored.
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 here.
Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
Connect the fuel pump connector.
Install the rear floor service hole cover with new butyl tape.
Install the rear seat cushion assembly Click here.
FUEL LINE
When disconnecting a high pressure fuel line, a large amount of fuel will spray, so perform the following procedure:
Discharge fuel system pressure (Step 2).
Disconnect the fuel tank main tube sub-assembly.
Drain the fuel that remains in the fuel tank main tube sub-assembly.
Cover the disconnected fuel tank main tube sub-assembly with a plastic bag to prevent damage and contamination.
Place a container under the connectors.
*1 | No. 2 Fuel Pipe Clamp |
*2 | Retainer |
*3 | Fuel Hose Clamp |
*4 | Fuel Tube Connector |
*a | Turn |
Perform the following procedure when disconnecting the fuel tube sub-assembly.
Note
Do not forcibly bend, kink or twist the fuel tube.
Disconnect the fuel tube from the fuel hose clamp.
Remove the No. 2 fuel pipe clamp.
Wipe off any foreign matter on the fuel tube connector.
Hold the fuel tube connector, and then install SST.
Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.
Insert SST into the fuel tube connector and hold it. Then push the fuel tube connector toward SST.
Mount the retainer of the fuel tube connector onto the chamfered part of SST.
*1 | Retainer |
*2 | O-ring |
*3 | Fuel Tube Sub-assembly |
*4 | Fuel Tube Connector |
*5 | Fuel Pipe |
Slide SST and the fuel tube connector together until they make a "click" sound, and then disconnect the fuel tube sub-assembly.
Drain the fuel remaining inside the fuel tube sub-assembly.
Cover the fuel tube and fuel pipe with plastic bags to protect the disconnected parts.
Perform the following procedure when connecting the fuel tube.
*1 | No. 2 Fuel Pipe Clamp |
*2 | Fuel Hose Clamp |
Check if there is any damage or foreign matter on the fuel pipe connections.
Match the axis of the fuel tube connector with the axis of the fuel pipe, and push it into the fuel tube connector until the fuel tube connector makes a "click" sound. If the connection is tight, apply a small amount of clean engine oil to the tip of the fuel pipe.
After finishing the connection, check if the fuel pipe and the fuel tube connector are securely connected by pulling on them.
Push | |
Pull |
Inspect for fuel leaks.
Install a new No. 2 fuel pipe clamp.
Connect the fuel tube to the fuel hose clamp.
Perform the following procedure when disconnecting the fuel tube connector (quick type A):
Remove the No. 1 fuel pipe clamp.
Check whether there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it. Clean it if necessary.
*1 | Retainer |
*2 | O-ring |
*3 | Fuel Tube Connector |
*4 | Fuel Pipe |
Pinch | |
Pull Out |
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.
If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release it. Pull the fuel tube connector out of the fuel pipe carefully.
Note
Be sure to disconnect the fuel tube connector by hand.
Check that there is no foreign matter on the sealing surfaces of the disconnected fuel pipes. Clean the surfaces if necessary.
Cover the disconnected fuel pipe and fuel tube connector with a plastic bag to prevent damage and contamination.
Perform the following procedure when connecting a fuel tube connector (quick type A):
Check if there is any damage or foreign matter on the connecting parts of the fuel pipe.
Line up the 2 parts of the fuel lines 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.
After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
Inspect for fuel leaks Click here.
Install the No. 1 fuel pipe clamp.
Perform the following procedure when disconnecting a fuel tube connector (quick type B):
*1 | Retainer |
Before disconnecting the fuel tube connector, clean off any foreign matter that may be present.
Pinch the tabs of the retainer to disengage the 2 claws. Push the retainer down as shown in the illustration.
Note
Be sure to disconnect the fuel tube connector by hand.
If the fuel tube connector and fuel pipe are stuck, push and pull on the fuel tube connector while holding the fuel pipe by hand. Pull the 2 fuel lines apart to separate the fuel tube connector.
Note
Be sure to disconnect the fuel tube connector by hand.
Check that there is foreign matter on the contact surface of the disconnected fuel pipe. Clean it if necessary.
Cover the disconnected fuel pipe and fuel tube connector with a plastic bag to prevent damage and contamination.
Perform the following procedure when connecting the fuel tube connector (quick type B):
Line up the 2 parts of the fuel lines 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.
After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
Inspect for fuel leaks Click here.
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 EPDM protector on the outside of the nylon tube.
Do not pinch or kink the nylon tubes to prevent fuel leakage.
INJECTOR
*1 | Fuel Delivery Pipe |
*2 | O-ring |
*3 | Fuel Injector Assembly |
*4 | Injector Vibration Insulator |
Install the fuel injector assembly to the fuel delivery pipe and the cylinder head as shown in the illustration.
Note
Before installing the fuel injector assembly, be sure to apply a light coat of fuel or spindle oil where the fuel delivery pipe contacts the O-ring.
*1 | O-ring |
*2 | Fuel Delivery Pipe |
*a | CORRECT |
*b | INCORRECT |
Observe the following precautions when removing and installing the fuel injector assemblies:
Do not reuse the O-ring and injector vibration insulator.
When placing a new O-ring on the fuel injector assembly, do not damage the O-ring.
Coat a new O-ring with spindle oil or fuel before installing it.
Note
Do not use engine oil, gear oil or brake fluid.
FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
*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 fuel suction plate sub-assembly.
INSPECT FOR FUEL LEAK
Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs Click here.