Fuel Delivery and Air Induction: Service Precautions

WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury:

- Keep a dry chemical (Class B) fire extinguisher near the work area.
- Place a "CAUTION FLAMMABLE" sign in the work area.
- Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away.
- Wear eye protection.
- Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).)
- Relieve the fuel system pressure prior to disconnecting fuel system components.
- Disconnect the negative battery cable except for tests where battery voltage is required.
- Use a suitable container to store or catch fuel.
- Do not replace fuel pipe with fuel hose.
- Plug all disconnected fuel line fittings and hoses.
- After making any fuel system repairs ALWAYS inspect for fuel leaks.

Hose Connection:

- Work must be done with no smoking, in a well-ventilated area and away from any open flames.
- As fuel feed line (between fuel pump and fuel pressure regulator) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected. Before loosening or disconnecting fuel feed line, make sure to release fuel pressure according to "Fuel Pressure Relief Procedure:".

A small amount of fuel may be released after the fuel line is disconnected.

In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop cloth. Put that cloth in an approved container when disconnection is completed.

- Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
- Fuel or fuel vapor hose (1) connection varies with each type of pipe (2). When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to figure "Hose Connection".
After connecting, make sure that it has no twist or kink.
- When installing fuel union bolt gasket, always use new gasket and tighten union bolt to specified torque according to "Tightening Torque Specifications: " for fuel system.
- When installing injector, fuel feed pipe or fuel pressure regulator, lubricate its O-ring with gasoline.
- When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified torque.