Vehicle Damage Warnings

FUEL SYSTEM

PRECAUTION

1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
4. DISCHARGE FUEL SYSTEM PRESSURE

NOTE:
- Perform the given procedures to prevent fuel from spilling out before removing any fuel system parts.
- Pressure will still remain in the fuel line even after performing the given procedures. When disconnecting the fuel line, cover the opening with a shop rag or a piece of cloth to prevent fuel from spraying.

a. Remove the F/PMP fuse.
1. Remove the No. 2 relay block cover UPR.
2. Remove the F/PMP fuse.
3. Start the engine.
4. After the engine has stopped, turn the engine switch off.

HINT: DTC P0171/25 (fuel problem) and/or P0191/49 (fuel pressure sensor signal error) may be detected.

5. Crank the engine again. Check that the engine does not start.
6. Remove the fuel tank cap to discharge pressure from the fuel tank.
7. Disconnect the negative (-) battery terminal cable.
8. Reinstall the F/PMP fuse.




b. Disconnecting the fuel pump connector.
1. Remove the rear seat cushion.
2. Remove the rear floor service hole cover.
3. Disconnect the fuel pump connector.
4. Start the engine.
5. After the engine has stopped, turn the engine switch off.

HINT: DTC P0171/25 (fuel problem) and/or P0191/49 (fuel pressure sensor signal error) may be detected.

6. Crank the engine again. Check that the engine does not start.
7. Remove the fuel tank cap to discharge pressure from the fuel tank.
8. Disconnect the cable from the negative (-) battery terminal.
9. Reconnect the fuel pump connector.
10. Install the rear floor service hole cover.
11. Install the rear seat.

5. FUEL SYSTEM
a. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out. Follow these procedures:
1. Perform the "discharge the fuel system pressure" procedures given.
2. Disconnect the fuel tube.
3. Drain the fuel remaining inside the fuel tube.
4. To protect the disconnected fuel pump tube from damage and contamination, cover it with a plastic bag.




5. Place a container under the connection.

b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, follow these procedures:




1. Always use 2 new gaskets.
2. Tighten the union bolt with your hands.




3. Using SST, tighten the union bolt to the specified torque.

Torque:
39 N.m (397 kgf.cm, 29 ft.lbf) for use without SST
33 N.m (337 kgf.cm, 24 ft.lbf) for use with SST

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).




c. When connecting the flare nut on the high pressure pipe union, follow these procedures:
1. Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand.
2. Using SST, tighten the flare nut to the specified torque.

Torque:
35 N.m (357 kgf.cm, 26 ft.lbf) for use without SST
28 N.m (286 kgf.cm, 21 ft.lbf) for use with SST

NOTE: Do not rotate the fuel main tube when tightening the flare nut.

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).




d. Follow these precautions when removing and installing the injector.
1. Never reuse the O-ring.
2. When placing a new O-ring on the injector, take care not to damage it.
3. Coat a new O-ring with spindle oil or gasoline before installation. Never use engine, gear or brake oil.




e. Install the injector to the delivery pipe and lower the intake manifold as shown in the illustration. Before installing the injector, apply spindle oil or gasoline to where the delivery pipe and intake manifold contact the O-ring.




f. Observe these precautions when disconnecting the fuel tube connector (quick type).
1. Disengage the lock claw by lifting up the cover, as shown in the illustration.
2. If the connector and pipe are stuck, pinch the connector, and push and pull the pipe to disconnect them. Do not use any tools.




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




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

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




1. Check that there is no damage or foreign matter on the part of the pipe that contacts the connector.
2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a 'click' sound. If the connection is too tight, apply a small amount of fresh engine oil on the tip of the pipe.




3. After connecting the pipe and connector, try to pull them apart to confirm that they are securely connected.
4. Install the No. 1 fuel pipe clamp to the connector.

6. CHECK FOR FUEL LEAKS
a. Make sure that there are no fuel leaks after performing maintenance on the fuel system.




1. Connect the intelligent tester to the DLC3.
2. Turn the engine switch on (IG), and push the intelligent tester main switch ON.

NOTE: Do not start the engine.

3. Select the ACTIVE TEST mode on the intelligent tester.

HINT: Refer to the intelligent tester operator's manual for further details.

4. Check that there are no leaks from the fuel system.
5. Turn the engine switch off.
6. Disconnect the intelligent tester from the DLC3.