7GR-FKS FUEL FUEL SYSTEM PRECAUTION
- CAUTION:
- ·
Never perform work on fuel system components near any possible ignition sources.
·Vaporized fuel could ignite, resulting in a serious accident.
·
Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.
·Sparks could cause vaporized fuel to ignite, resulting in a serious accident.
·
The fuel tank assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the fuel tank assembly may fall off the engine lifter.
·
To prevent serious injury due to fuel spray from the high-pressure fuel lines, always discharge fuel system pressure before removing any fuel system components.
BEFORE WORKING ON FUEL SYSTEM
Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.
- NOTICE:
-
After turning the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) battery terminal.
Do not smoke or work near fire when handling the fuel system.
Keep fuel away from rubber or leather parts.
DISCHARGE FUEL SYSTEM PRESSURE
- CAUTION:
- ·
Make sure the engine coolant temperature is 60°C (140°F) or less when performing this procedure.
·Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
·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.
Remove the rear seat assembly (except Wagon).
for Commuter, 3-Passenger Seat with 2-Point Type Seat Belt and Headrest:
for Commuter, 3-Passenger Seat with 2-Point Type Seat Belt without Headrest:
for Commuter, 3-Passenger Seat with 3-Point Type Seat Belt:
for Commuter, 4-Passenger Seat:
for Commuter, Single-Passenger Seat with 2-Point Type Seat Belt:
for Commuter, Single-Passenger Seat with 3-Point Type Seat Belt:
for Commuter, 2-Passenger Seat with 3-Point Type Seat Belt:
for Commuter, 2-Passenger Seat with 2-Point Type Seat Belt and Headrest:
for Commuter, 2-Passenger Seat with 2-Point Type Seat Belt without Headrest:
Remove the fuel tank inspection hole cover.
Disconnect the fuel pump connector.
Start the engine. After the engine stops, turn the engine switch off.
- NOTICE:
-
Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.
Check that the engine does not start.
- HINT:
-
If the engine does not stop naturally, perform direct injection by racing the engine to reduce the fuel pressure [Fuel Pressure (High)] and stop the engine.
Remove the fuel tank cap and let the air out of the fuel tank.
Disconnect the cable from the negative (-) battery terminal.
- NOTICE:
- ·
After turning the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) battery terminal.
·When disconnectuing and reconnecting the negative (-) battery terminal.
Connect the fuel pump connector.
Install the fuel tank inspection hole cover.
Install the rear seat assembly (except Wagon).
for Commuter, 3-Passenger Seat with 2-Point Type Seat Belt and Headrest:
for Commuter, 3-Passenger Seat with 2-Point Type Seat Belt without Headrest:
for Commuter, 3-Passenger Seat with 3-Point Type Seat Belt:
for Commuter, 4-Passenger Seat:
for Commuter, Single-Passenger Seat with 2-Point Type Seat Belt:
for Commuter, Single-Passenger Seat with 3-Point Type Seat Belt:
for Commuter, 2-Passenger Seat with 3-Point Type Seat Belt:
for Commuter, 2-Passenger Seat with 2-Point Type Seat Belt and Headrest:
for Commuter, 2-Passenger Seat with 2-Point Type Seat Belt without Headrest:
FUEL LINE
When disconnecting a high-pressure fuel line, a large amount of fuel will spray. Perform the following procedure:
Discharge fuel system pressure.
Disconnect the fuel tube.
Drain the fuel remaining inside the fuel tube into a container.
Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
Put a container under the connection.
Quick Type A:
Perform the following procedure when disconnecting a fuel tube connector.
- NOTICE:
-
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
| *a | Fuel Tube Connector Cover |
Remove the fuel tube connector cover.
Check for dirt or mud on the fuel pipe and around the connector before disconnection. Clean if necessary.
| *a | Retainer |
|
Pinch |
|
Pull |
If the connector and the fuel pipe are stuck, pinch the connector, push and pull the fuel pipe to disconnect the pipe and pull it out.
- NOTICE:
- ·
0.927,0.26 0.792,0.26 0.792,0.26 0.615,0.823 false 2.51,0.271 2.417,0.271 2.417,0.271 2.271,0.844 false 1.313,1.313 1.313,1.823 false 1.479,1.833 1.083,1.833 1.083,1.833 1.083,1.323 false 2.313,1.833 2.198,1.833 2.198,1.833 1.854,1.354 false 0.271,1.813 0.125,1.813 0.125,1.813 0.125,1.573 false 0.125,1.573 0.25,1.26 false 0.958,0.177 1.167,0.396 0.208,0.219 10 false *a 2.365,1.74 2.573,1.948 0.208,0.208 10 false *e 1.521,1.76 1.76,1.99 0.24,0.229 10 false *d 0.292,1.729 0.51,1.938 0.219,0.208 10 false *c 2.542,0.177 2.781,0.396 0.24,0.219 10 false *b*a Retainer *b Nylon Tube *c Fuel Pipe *d O-Ring *e Fuel Tube Connector
Check for foreign matter in the fuel pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the fuel pipe and connector.
·Do not use any tools to separate the fuel pipe and connector.
·Do not forcefully bend or twist the nylon tube.
·Check for foreign matter on the fuel pipe seal surface. Clean if necessary.
·Put the fuel pipe and connector ends in plastic bags to prevent damage and foreign matter contamination.
·If the fuel pipe and connector are stuck together, pinch the connector between your fingers and turn it carefully to disconnect it.
Check for dirt or mud on the seal surface of the disconnected fuel pipe. Clean if necessary.
To protect the disconnected fuel pipe and connector from damage and contamination, cover them with a plastic bag.
Quick Type A:
Perform the following procedure when disconnecting a fuel tube connector.
- NOTICE:
-
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
Check that there is no damage or contamination in the connected part of the fuel pipe.
|
|
Push |
Align the axis of the connector with the axis of the fuel pipe. Push the fuel pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil to the tip of the fuel pipe.
|
|
Pull |
After connecting the fuel pipe and the connector, check that the fuel pipe and connector are securely connected by trying to pull them apart.
Install the fuel tube connector cover.
Check for any fuel leaks.
Quick Type B:
Perform the following procedure when disconnecting a fuel tube connector.
- NOTICE:
-
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
Check that there is no damage or foreign matter on the part of the fuel pipe that contacts the connector.
| *a | Retainer |
|
|
Push |
|
|
Down |
|
Pull |
Detach the 2 claws of the connector retainer. Push down on the connector and disconnect it from the pipe.
- HINT:
-
0,0 0,0 false
Pull
Push
-
If the connector and fuel pipe are stuck, pinch the fuel pipe by hand and push and pull the connector to disconnect it.
- NOTICE:
-
1.052,1.594 1.052,1.354 false 1.896,1.188 1.896,1.708 false 2.125,1.719 1.708,1.719 1.708,1.719 1.708,1.198 false 0.604,0.302 0.521,0.302 false 0.521,0.302 0.521,0.927 false 1.438,0.302 1.365,0.302 1.365,0.302 1.094,0.74 false 2.948,0.302 2.875,0.302 2.875,0.302 2.729,0.781 false 0.656,0.24 0.969,0.396 0.313,0.156 10 false *b 1.5,0.229 1.813,0.385 0.313,0.156 10 false *a 2.979,0.229 3.292,0.385 0.313,0.156 10 false *c 0.938,1.615 1.25,1.771 0.313,0.156 10 false *d 2.177,1.635 2.49,1.792 0.313,0.156 10 false *e*a Retainer *b Fuel Pipe *c Nylon Tube *d Fuel Tube Connector *e O-Ring
- ·
Check for any dirt and foreign matter contamination in the fuel pipe and around the connector. Clean if necessary. Foreign matter may damage the O-ring or cause leaks in the seal between the fuel pipe and connector.
·Do not use any tools to separate the fuel pipe and connector.
·Do not allow any scratches or foreign matter on the parts when disconnecting them, as the fuel tube joint contains the O-rings that seal the plug.
·Check for any dirt and foreign matter on the fuel pipe seal surface. Clean if necessary.
·Do not forcibly bend, twist or turn the nylon tube.
·Protect the disconnected part by covering it with a plastic bag and tape after disconnecting the main tube.
·If the fuel pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the main tube.
Check for foreign matter on the seal surface of the disconnected fuel pipe. Clean it if necessary.
To protect the disconnected fuel pipe and connector from damage and foreign matter, cover them with a plastic bag.
Quick Type B:
Perform the following procedure when disconnecting a fuel tube connector.
- NOTICE:
-
Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.
Check for foreign matter on the fuel pipe and around the connector before connecting it. Clean it if necessary.
| *a | Retainer |
| *b | Claw |
|
|
Push |
|
|
Push in |
|
|
Pull |
Align the axis of the connector with the axis of the fuel pipe. Push the fuel pipe into the connector, and then push up on the retainer.
- NOTICE:
- ·
Before connecting the tube connectors to the fuel pipes, check if there is any damage or foreign matter in the connectors.
·After connecting the fuel pipe and the connector, check that the fuel pipe and connector are securely connected by trying to pull them apart.
FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
- NOTICE:
- ·
0.26,1.75 0.698,1.75 true 2.146,1.906 2.583,1.906 true 0.083,1.656 0.323,1.854 0.24,0.198 10 false *a 2.625,1.802 2.865,2 0.24,0.198 10 false *a*a 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 pressed into the fuel suction plate sub-assembly.
·When replacing the fuel filter, replace it together with the fuel suction plate sub-assembly.
INSPECT FOR FUEL LEAK
Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.