FUEL SYSTEM PRECAUTION


  1. BEFORE WORKING ON FUEL SYSTEM


    1. When disconnecting a fuel line, fuel will spray. So observe the following precautions:


      1. Do not smoke or work near fire when handling the fuel system.

      2. 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 shop rag or a piece of cloth to prevent fuel from spraying or coming out.


    1. Remove the rear seat cushion assembly Click here.

    2. Remove the rear floor service hole cover.

    3. B001NRV

      Disconnect the fuel pump connector.

    4. Start the engine.

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

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

      Tech Tips

      DTC P0171/74 (fuel problem) may be stored.

    7. 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.

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

    9. Connect the fuel pump connector.

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

    11. Install the rear seat cushion assembly Click here.

  3. FUEL LINE


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


      1. Discharge fuel system pressure (Step 2).

      2. Disconnect the fuel tank main tube sub-assembly.

      3. Drain the fuel that remains in the fuel tank main tube sub-assembly.

      4. Cover the disconnected fuel tank main tube sub-assembly with a plastic bag to prevent damage and contamination.

      5. Place a container under the connectors.

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


      1. B001OBXE02
        Text in Illustration
        *1 No. 1 Fuel Pipe Clamp
        *2 No. 2 Fuel Pipe Clamp

        Remove the fuel pipe clamp.

      2. Check that there is no dirt or other foreign matter on the fuel pipe before disconnecting it. Clean it if necessary.

      3. Disconnect the fuel tube connector from the fuel pipe by hand.

      4. B001NR9E47
        Text in Illustration
        *1 Retainer
        *2 O-ring
        *3 Fuel Tube Connector

        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 out of the fuel pipe carefully.

      5. Check that there is no foreign matter on the contact surface of the disconnected fuel pipe. Clean it 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. B001OIH

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

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

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

      4. Inspect for fuel leaks Click here.

      5. Install the fuel pipe clamp.

    4. B001OA0E01

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

      Text in Illustration
      *1 Retainer

      1. Check that there is no damage or foreign matter on the connecting part of the fuel pipe.

      2. Disengage the 2 claws of the retainer. Pull down the retainer and disconnect the fuel tube connector from the fuel pipe.

        Tech Tips

        Be sure to disconnect it by hand.

      3. B001OJL

        If the fuel tube connector and fuel pipe are stuck, pinch the fuel pipe by hand and push and pull the fuel tube connector to disconnect it.

      4. Check for foreign matter on the seal surface of the disconnected fuel pipe. Clean it 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. B001NY4

        Line up the two 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.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube 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 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.

  4. INJECTOR


    1. B001OFTE09
      Text in Illustration
      *1 Fuel Delivery Pipe Sub-assembly
      *2 O-ring
      *3 Fuel Injector Assembly
      *4 Injector Vibration Insulator
      *5 Intake Manifold

      Install the fuel injector assembly to the fuel delivery pipe sub-assembly and the lower intake manifold as shown in the illustration.

      Note

      Before installing the fuel injector assembly, be sure to apply spindle oil or fuel where the fuel delivery pipe sub-assembly or intake manifold contacts O-rings.

    2. B001OI2E02
      Text in Illustration
      *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 insulator.

      2. When placing a new O-ring on the fuel injector assembly, do not damage the O-ring.

      3. Coat a new O-ring with spindle oil or fuel before installing it.

        Note

        Do not use engine oil, gear oil or brake fluid.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. B001O5ME01
      Text in Illustration
      *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.

  6. INSPECT FOR FUEL LEAK


    1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system Click here.