FUEL SYSTEM PRECAUTION

  1. IGNITION SWITCH EXPRESSION

    Tip:

    The type of ignition switch used on this model differs according to 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

    Off

    Off

    Ignition Switch ON

    ON

    On (IG)

    Ignition Switch ACC

    ACC

    On (ACC)

    Engine Start

    START

    Start

  2. 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 gasoline away from rubber or leather parts.

  3. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:

    • Perform the following procedures before removing any fuel system parts to prevent fuel from spilling out.

    • Pressure will still remain in the fuel lines even after performing the following procedures. When disconnecting a fuel line, cover it with a piece of cloth to prevent fuel from spraying or coming out.

    1. with Rear No. 1 seat:

      1. Remove the rear No. 1 seat (Click here).

      2. Remove the rear center seat (Click here).

    2. A212512

      Remove the rear floor service hole cover.

    3. Disconnect the connector from the fuel pump.

    4. Start the engine. After the engine stops naturally, turn the ignition switch off.

      Note:

      Do not increase the engine speed or drive the vehicle while waiting for the engine to stop naturally.

      Tip:

      If DTC P0171 (system too lean) is output, clear the DTC (Click here).

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

    6. Remove the fuel tank cap and discharge the pressure from the fuel tank.

    7. Disconnect the cable from the negative battery terminal.

      Note:

      • 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 (Click here).

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

    8. Connect the connector of the fuel pump.

  4. FUEL LINE

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

      1. Discharge fuel system pressure.

      2. Disconnect the fuel tube.

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

      4. A390576E01

        To prevent damage and contamination, cover the disconnected pipe and connector with a plastic bag.

        Table 1. Text in Illustration

        *1

        Plastic Bag
    2. A076220E58

      Perform the following procedure when disconnecting a fuel delivery pipe (for Metallic Type):

      Tip:

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

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

        Table 2. Text in Illustration

        *1

        O-Ring

        *2

        Retainer

        *3

        Pipe

        *4

        Nylon Tube

        *5

        Fuel Tube Connector
      2. A208579E03

        Remove the No. 2 fuel pipe clamp.

        Table 3. Text in Illustration

        *1

        No. 2 fuel pipe clamp

        *2

        Claw
        Note:

        Do not reuse the fuel pipe clamp.

      3. Find the metallic connector of the fuel tube.

      4. A062165E13

        Install SST to the connector as shown in the illustration.

        09268-21010

      5. A062156E17

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

      6. Slide SST and the connector together towards the fuel tube.

    3. Perform the following procedure when connecting a fuel tube connector (for Metallic Type):

      1. Check if there is any damage or foreign objects on the pipe connection area.

      2. A142841E01

        Match the axis of the connector with the axis of the pipe, and push the pipe into the connector until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe.

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

      4. A208579E03

        Install a new No. 2 fuel pipe clamp.

        Table 4. Text in Illustration

        *1

        No. 2 fuel pipe clamp

        *2

        Claw

      5. Inspect for fuel leak.

    4. Perform the following procedure when disconnecting a fuel tube connector (for Quick Type A):

      1. A208580E03

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

        Table 5. Text in Illustration

        *1

        No. 1 Fuel Pipe Clamp
      2. A099425E32

        Detach the lock claw by raising the fuel hose connector cover as shown in the illustration.

        Table 6. Text in Illustration

        *1

        Fuel Hose Connector Cover

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

      4. Disconnect the connector from the pipe by hand.

      5. A159424E51

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

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

      7. A099427E35

        Do not damage the disconnected pipe or connector, and prevent entry of foreign objects by covering them with plastic bags.

        Table 7. Text in Illustration

        *1

        Plastic Bag

    5. Perform the following procedure when connecting a fuel tube connector (for Quick Type A):

      1. A121423E15

        Check if there is any damage or foreign objects on the pipe connection.

      2. Line up the two parts of the pipes to be connected and push them together until the connector makes a "click" sound. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it.

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

      4. A390577E01

        Attach the lock claws to the connector by pushing down on the fuel hose connector cover.

        Table 8. Text in Illustration

        *1

        Fuel Tube Connector Cover
      5. A208580E03

        Attach the lock claws and install the No. 1 fuel pipe clamp.

        Table 9. Text in Illustration

        *1

        No. 1 Fuel Pipe Clamp

      6. Inspect for fuel leak.

    6. A129459

      Observe these precautions when disconnecting the fuel tube connector (for quick type B).

      1. Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.

      2. Detach the 2 claws of the connector retainer, push down on the connector and disconnect it from the pipe.

        Note:

        Do not use any tools in this procedure.

      3. A091246

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

      4. Check for foreign matter on the seal surface of the disconnected pipe. Clean if necessary.

      5. A103972

        To protect the disconnected connector from damage and foreign matter, cover it with a plastic bag.

    7. A132390

      Observe these precautions when connecting the fuel tube connector (for quick type B).

      1. Check for foreign matter on the pipe and around the connector before connecting them. Clean if necessary.

      2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector, and then push up on the retainer.

      3. A093435

        After connecting the pipe and connector, try to pull them apart to confirm that they are securely connected.

      4. Check for fuel leaks.

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

      Note:

      • Do not twist the connection part of the nylon tube and quick connector when connecting them.

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

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

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

  5. INJECTOR

    1. A161731

      Observe the following precautions when removing and installing the fuel injector.

      1. Do not reuse an O-ring or insulator.

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

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

    2. A211322E01

      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.

      Table 10. Text in Illustration

      *1

      Delivery Pipe

      *2

      O-Ring

      *3

      Insulator

  6. FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE

    1. A390579E01

      Do not disconnect the tube shown in the illustration when disassembling the fuel suction tube with pump and gauge. Doing so will cause reassembly of the fuel suction tube with pump and gauge to be impossible as the tube is welded to the plate.

      Table 11. Text in Illustration

      *1

      Tube