CAUTION:
Never perform work on fuel system components near any possible ignition sources.
Vaporized fuel could ignite, resulting in a serious accident.
Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
Because the weight of the fuel tank sub-assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.
If work is not performed according to the procedures described in the repair manual, there is a danger that the components could fall down.
IGNITION SWITCH EXPRESSIONS
The type of ignition switch used on this model differs depending on 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 (Lock) |
Ignition Switch ACC | ACC | On (ACC) |
Ignition Switch ON | ON | On (IG) |
Engine Start | START | On (Start) |
PRECAUTION
Note
Keep fuel away from rubber or leather parts.
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.
DISCHARGE FUEL SYSTEM PRESSURE
Note
Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
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.
When discharging fuel system pressure by disconnecting the EFI MAIN NO. 2 relay:
Remove the No. 1 relay block cover.
Remove the EFI MAIN NO. 2 relay.
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.
Crank the engine again and make sure that the engine does not start.
Tech Tips
DTC P008700 (Fuel Rail / System Pressure - Too Low), P017100 (System Too Lean), P160300 (Engine Stall History), P160400 (Startability Malfunction) or P160500 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.
Remove the fuel tank cap and discharge the pressure from the fuel tank assembly.
Disconnect the cable from the negative (-) battery terminal.
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Install the EFI MAIN NO. 2 relay.
Install the No. 1 relay block cover.
When discharging fuel system pressure by disconnecting the fuel pump connector:
Disconnect the rear center seat outer belt assembly.
Remove the bench type rear seat cushion assembly.
Remove the rear seat cushion lock hook.
*A | for 2WD |
*B | for AWD |
Remove the rear floor service hole cover.
for 2WD:
for AWD:
Disconnect the fuel suction tube with pump and gauge assembly connector.
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.
Crank the engine again and make sure that the engine does not start.
Tech Tips
DTC P008700 (Fuel Rail / System Pressure - Too Low), P017100 (System Too Lean), P160300 (Engine Stall History), P160400 (Startability Malfunction) or P160500 (Rough Idling) may be stored. Clear the DTCs before proceeding to the next step.
Remove the fuel tank cap assembly and discharge the pressure from the fuel tank assembly.
Disconnect the cable from the negative (-) battery terminal.
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Connect the fuel suction tube with pump and gauge assembly connector.
Install the rear floor service hole cover.
for 2WD:
for AWD:
Install the rear seat cushion lock hook.
Install the bench type rear seat cushion assembly.
Connect the rear center seat outer belt assembly.
FUEL LINE
When disconnecting a high-pressure fuel line, a large amount of fuel will spray. Perform the following procedure:
Discharge fuel system pressure.
Disconnect the fuel tube.
Drain the fuel remaining inside the fuel pump tube into a container.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
Quick Type A:
Perform the following procedure when disconnecting a fuel tube connector.
Note
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
Open the cover of the No. 1 fuel pipe clamp and remove the No. 1 fuel pipe clamp from the fuel tube connector. (Cover Type A)
Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.
Release the lock of the fuel tube connector cover. (Cover Type B)
Check whether there is any foreign matter on the fuel pipe around the fuel tube connector before disconnecting it and remove the foreign matter as necessary.
*a | Retainer |
*b | O-ring |
*c | Fuel Tube Connector |
*d | Nylon Tube |
*e | Fuel Pipe |
Pinch | |
Pull off |
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 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.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
Do not bend, twist, pinch or kink the nylon tube.
Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
Quick Type A:
Perform the following procedure when connecting a fuel tube connector.
Note
Check that there is no damage or foreign matter on the connecting parts of the fuel lines.
Pull |
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 gasoline 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.
Install the No. 1 fuel pipe clamp to the fuel tube connector and close the cover of the No. 1 fuel pipe clamp. (Clamp Type A)
Engage the lock of the fuel tube connector cover. (Cover Type B)
Inspect for fuel leaks.
Quick Type B:
Perform the following procedure when disconnecting a fuel tube connector.
Note
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
*a | Retainer |
*b | Fuel Pipe |
*c | Nylon Tube |
*d | Fuel Tube Connector |
*e | O-ring |
*f | Claw |
Push | |
Pull out | |
Pull off |
Disengage the 2 claws of the retainer. Pull out the retainer and disconnect the fuel tube connector from the fuel pipe.
Note
Be sure to disconnect the fuel tube connector by hand.
If the fuel tube connector and 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.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
Do not bend, twist, pinch or kink the nylon tube.
Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
Quick Type B:
Perform the following procedure when connecting a fuel tube connector.
Note
Check that there is no damage or foreign matter on the connecting parts of the fuel lines.
*a | Retainer |
*b | Claw |
Push | |
Push in |
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 gasoline to the tip of the fuel pipe and reinsert it.
Connect the fuel lines and push in the retainer to engage the 2 claws. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
Inspect for fuel leaks.
Quick Type C:
Perform the following procedure when disconnecting a fuel tube connector.
Note
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
*a | Fuel Tube Connector |
*b | Fuel Pipe |
*c | Retainer |
*d | O-ring |
Pinch | |
Pull off |
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 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.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).
Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
Quick Type C:
Perform the following procedure when connecting a fuel tube connector.
Note
Check that there is no damage or foreign matter on the connecting parts of the fuel lines.
Pull |
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 gasoline 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.
Quick Type D:
Perform the following procedure when disconnecting a fuel tube connector.
Note
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
*a | Retainer |
Pull out | |
Pull off |
Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.
Note
Be sure to disconnect the fuel tube connector by hand.
*a | Retainer |
*b | O-ring |
*c | Fuel Tube Connector |
*d | Fuel Pipe |
If the fuel tube connector and 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.
Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).
Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
Quick Type D:
Perform the following procedure when connecting a fuel tube connector.
Note
Check that there is no damage or foreign matter on the connecting parts of the fuel lines.
*a | Retainer |
Push | |
Push in |
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 gasoline to the tip of the fuel pipe and reinsert it.
Connect the fuel lines and push in the retainer. Check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
Inspect for fuel leaks.
*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 nylon tube of the fuel tube connector or fuel tube connector when connecting it.
Do not remove the Ethylene Propylene Diene Monomer (EPDM) rubber protector on the outside of the nylon tube.
Do not bend, twist, pinch or kink the nylon tube.
FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
Note
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.
When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.
*a | Tube |
INSPECT FOR FUEL LEAK
Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.