FUEL SYSTEM PRECAUTION


  1. PRECAUTIONS


    1. Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) auxiliary battery terminal.

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

    3. Keep gasoline away from rubber or leather parts.

  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 piece of cloth to prevent fuel from spraying or coming out.


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

    2. Remove the rear No. 1 seat assembly (for Center) Click here.

    3. Remove the rear No. 2 seat assembly Click here.

    4. Remove the rear floor service hole cover Click here.

    5. A005C63

      Disconnect the fuel pump connector.

    6. Put the engine in inspection mode Click here.

    7. Start the engine.

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

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

      Tech Tips

      Some DTCs may be stored. Clear the DTCs before proceeding to the next step Click here.

    10. Disconnect the cable from the negative (-) auxiliary battery terminal.

      Note

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

    11. Connect the fuel pump connector.

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

    13. Install the rear floor service hole cover with new butyl tape Click here.

    14. Install the rear No. 2 seat assembly Click here.

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

    16. Install the rear No. 1 seat assembly (for Side) Click here.

  3. FUEL LINE


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


      1. Discharge the fuel system pressure.

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

      3. Drain the fuel remaining inside the fuel tank main tube sub-assembly into a container.

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

    2. A005ABWE66

      Perform the following procedure when disconnecting a fuel delivery pipe (metallic type):

      Text in Illustration
      *1 Retainer
      *2 O-ring
      *3 Nylon Tube
      *4 Fuel Tube Connector
      *5 Fuel Pipe

      Tech Tips

      The structure of a fuel tube connector is as shown in the illustration.


      1. Check if there is any damage or foreign matter on the fuel pipe connections.

      2. A005E64E04
        Text in Illustration
        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B

        Remove the No. 2 fuel pipe clamp.

        Note

        Do not reuse the fuel pipe clamp (Type B).

      3. A005B2FE16

        Assemble SST to the fuel tube connector as shown in the illustration.

        SST
        09268-21011
      4. A005ABEE19
        Text in Illustration
        *1 Retainer (4 places)
        *a Turn
        *b Push

        Turn SST, align the retainers inside the fuel tube connector with the SST chamfers and insert SST into the fuel tube connector.

      5. Slide SST and the fuel tube connector together towards the fuel tube assembly.

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


      1. Check if there is any damage or foreign matter on the fuel pipe connections.

      2. A005BF7E02
        Text in Illustration
        *a Push
        *b Pull

        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 the fuel tube connector are securely connected by pulling on them.

      4. A005BVXE04
        Text in Illustration
        *1 No. 2 Fuel Pipe Clamp
        *a Type A
        *b Type B

        Install the No. 2 fuel pipe clamp. (Type A)

      5. Install a new No. 2 fuel pipe clamp. (Type B)

      6. Inspect for fuel leaks Click here.

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


      1. A005D70

        Release the claw and remove the No. 1 fuel pipe clamp.

      2. A005AG0E33
        Text in Illustration
        *1 Fuel Tube Connector Cover

        Disengage the lock claws by raising the fuel tube connector cover as shown in the illustration.

      3. Check that there is no dirt or other foreign matter on the fuel pipe and contact surface before disconnecting them. Clean them if necessary.

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

      5. A005BCOE53
        Text in Illustration
        *1 Retainer
        *2 O-ring
        *a Pinch
        *b Pull Out

        If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release them. Pull the fuel tube connector out of the fuel pipe carefully.

      6. Check that there is no dirt or other foreign matter on the contact surface of the disconnected fuel pipe. Clean them away if necessary.

      7. 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 A):


      1. A005AQ5E06
        Text in Illustration
        *a Push
        *b Pull

        Check if there is any damage or foreign matter on the fuel pipe connections.

      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. A005EP1E02
        Text in Illustration
        *1 Fuel Tube Connector Cover

        Engage the lock claws to the fuel tube connector by pushing down on the fuel tube connector cover.

      5. Inspect for fuel leaks Click here.

      6. A005D70

        Engage the lock claw and install the No. 1 fuel pipe clamp.

    6. A005AIHE01
      Text in Illustration
      *1 Retainer

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


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

      2. Using a screwdriver with its tip wrapped with protective tape, pull the tabs of the retainer to disengage the lock claws and pull out the fuel tank main tube.

      3. If the fuel tube connector and fuel pipe are stuck, pinch the fuel pipe by hand and push or 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.

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


      1. Check that there are no scratches or foreign matter around the connected part of the fuel tube connector and fuel pipe.

      2. A005BPSE01
        Text in Illustration
        *1 Retainer

        Align the fuel tube connector with the fuel pipe, connect the fuel tube connector and push the retainer in until the retainer makes a "click" sound to lock the claws of the retainer. If the connection is tight, apply a small amount of clean engine oil to the tip of the fuel pipe.

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

      4. Inspect for fuel leaks Click here.

    8. Observe the following precautions when handling a nylon tube.


      1. Do not twist the connection part of the nylon tube and the fuel tube connector when connecting them.

      2. Do not bend, kink, or twist the nylon tube.

      3. Do not remove the EPDM protector on the outside of the nylon tube.

      4. Do not close the piping by kinking the nylon tube.

  4. INJECTOR


    1. A005EGBE02
      Text in Illustration
      *1 O-ring
      *2 Delivery Pipe
      *a CORRECT
      *b INCORRECT

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


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

      2. When placing a new O-ring onto the injector, do not damage the new O-ring.

      3. Coat the new O-ring with grease or gasoline before installing it. Do not use engine oil, gear oil or brake fluid.

    2. A005BNFE08
      Text in Illustration
      *1 Delivery Pipe
      *2 O-ring
      3 Insulator

      Install the injector into the delivery pipe and cylinder head as shown in the illustration. Apply grease or gasoline to the contact surfaces of the injector before installing the injector.

  5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


    1. A005EIXE05
      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 plate.

  6. INSPECT FOR FUEL LEAK


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