Component Tests and General Diagnostics

WARNING: Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE REPAIR PROCEDURE".

CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign materials.

1. Disconnect the battery negative cable.
2. Disconnect the quick release connector from the pulsation damper as follows:




1. Push apart the lock clip and unlock it.




2. Lift the tab on the blue locking coupler until the fuel line can be released.
3. Pull the fuel hose straight back.

NOTE:
- The blue stopper may be removed from the quick connector. Be sure not to loose it. Reinstall it to the quick release connector before reconnecting the fuel line.




- The orange locking coupler has two internal locking tabs which retrain the pulsation damper pipe. Be sure that the tab on the locking coupler is rotated until it stops to release two internal locking tabs.

3. Push the SST quick release connector into the fuel distributor and fuel main hose into the SST until a click is heard.




4. Turn the lever on the SST as shown.
5. Connect the battery negative cable.






CAUTION: Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only.

6. Short the DLC terminal F/P to the body GND using a jumper wire.
7. Turn the ignition switch on and measure the fuel line pressure.
- If the pressure is higher than specified, inspect the fuel pump maximum pressure. If normal, inspect fuel return hose or the pressure regulator is clogged.
- If the pressure is lower than specified, proceed to Step (1).

Fuel line pressure: 270 - 310 kPa {2.7 - 3.2 kgf/sq.cm, 39 - 45 psi}




(1) Inspect change in the fuel line pressure while turning the lever as shown.
- If the fuel line pressure quickly increases, inspect the pressure regulator.
- If fuel line pressure gradually increases, inspect the fuel pump maximum pressure.
- If the fuel pump maximum pressure is normal, inspect for clogging between the fuel pump and the pressure regulator.

8. Turn off the ignition switch and disconnect the jumper wire
9. Observe the fuel pressure after 5 min. If the fuel hold pressure is lower than specified, proceed to step (1).

Fuel hold pressure
More than 150 kPa {1.5 kgf/sq.cm, 22 psi}




(1) Inspect changes in the fuel line pressure while turning the lever as shown.
- If the fuel line pressure holds, replace the pressure regulator.
- If the fuel line pressure does not hold, inspect the fuel leaks from the fuel line and the fuel injector.

10. Disconnect the SST.






NOTE: A checker tab is integrated with the quick release connector for new plastic fuel hoses. The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.

11. Inspect the plastic fuel hose and fuel pipe sealing surface for damage and deformation, and replace as necessary.
- If the quick release connector O-ring is damaged or has slipped, replace the plastic fuel hose.

12. Reconnect the fuel main hose to the fuel distributor until a click is heard.
13. Pull the quick release connector by hand and verify that it is installed securely.




14. Attach the lock clip to the quick release connector in the direction of the fuel distributor and lock it, as shown in the figure.