RM36D0EC _51 Engine / Hybrid System _083060 M20D-FKS FUEL _0403631 FUEL SYSTEM L

M20D-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.

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.

·

Perform the following procedure to prevent fuel from spraying before removing any fuel system parts.

·

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.

When discharging fuel system pressure by disconnecting the EFI MAIN NO. 2 relay:

Remove the engine room relay block cover.

ii.

Remove the EFI MAIN NO. 2 relay.

iii.

Remove the front fender front splash shield LH.

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iv.

Remove the front fender front splash shield RH.

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Remove the No. 1 engine under cover.

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vi.

Remove the No. 2 engine under cover assembly.

Click hereEngine / Hybrid System>M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL202004,202304,_51,_083059,_0403046,RM100000001N2I4_01_0004,202304,202405,_51,_083059,_0403046,RM1000000029XAE_01_0004,202405,202409,_51,_083059,_0403046,RM100000002JNSM_01_0004,202409,999999,_51,_083059,_0403046,RM100000002NRBV_01_0004,

vii.

0.469,0.625 0.469,0.354 0.469,0.354 0.625,0.354 false 2.417,0.531 2.521,0.313 2.521,0.313 2.677,0.313 false 0.688,0.271 1,0.427 0.313,0.156 10 false *a 2.719,0.219 3.031,0.375 0.313,0.156 10 false *a

*a	Lock Lever

Detach the claw and raise the lock lever to disconnect the No. 6 engine wire connector as shown in the illustration.

viii.

Start the engine. After the engine has stopped on its own, turn the ignition switch off.

NOTICE:: Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

ix.

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

HINT:: DTC P008700 (Fuel Rail / System Pressure - Too Low) and P017100 (System Too Lean) may be stored. Clear the DTCs before proceeding to the next step.; Click hereEngine / Hybrid System>M20D-FKS (ENGINE CONTROL)>SFI SYSTEM>DTC CHECK / CLEAR201910,202304,_51,_083058,_0401834,RM100000001JDWI,202304,202409,_51,_083058,_0401834,RM1000000029C72,202409,999999,_51,_083058,_0401834,RM100000002NA8O,

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

xi.

Disconnect the cable from the negative (-) battery terminal.

xii.

0.688,0.542 0.771,0.281 0.771,0.281 0.917,0.281 false 2.292,0.615 2.375,0.354 2.375,0.354 2.521,0.354 false 0.969,0.198 1.281,0.354 0.313,0.156 10 false *a 2.563,0.26 2.875,0.417 0.313,0.156 10 false *a

*a	Lock Lever

Connect the No. 6 engine wire connector and push down the lock lever to attach the claw as shown in the illustration.

xiii.

Install the No. 2 engine under cover assembly.

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xiv.

Install the No. 1 engine under cover.

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xv.

Install the front fender front splash shield LH.

Click hereEngine / Hybrid System>M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION201910,202304,_51,_083059,_0403046,RM100000001JN1K_01_0330,202304,999999,_51,_083059,_0403046,RM1000000029XAF_01_0330,

xvi.

Install the front fender front splash shield RH.

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xvii.

Install the EFI MAIN NO. 2 relay.

xviii.

Install the engine room relay block cover.

When discharging fuel system pressure by disconnecting the fuel pump connector:

Remove the bench type rear seat cushion assembly.

for GTMC Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for GTMC Made)>REMOVAL202004,999999,_58,_083102,_0419060,RM100000001MO2W_01_0022,

for SFTM Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for SFTM Made)>REMOVAL202004,999999,_58,_083102,_0419059,RM100000001MO2R_01_0022,

ii.

Remove the rear seat cushion lock hook.

for GTMC Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for GTMC Made)>REMOVAL202004,999999,_58,_083102,_0419060,RM100000001MO2W_01_0001,

for SFTM Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for SFTM Made)>REMOVAL202004,999999,_58,_083102,_0419059,RM100000001MO2R_01_0001,

iii.

Remove the rear floor service hole cover and butyl tape.

iv.

Disconnect the connector from the fuel suction with pump and gauge tube assembly.

Remove the front fender front splash shield LH.

vi.

Remove the front fender front splash shield RH.

vii.

Remove the No. 1 engine under cover.

viii.

Remove the No. 2 engine under cover assembly.

ix.

0.469,0.625 0.469,0.354 0.469,0.354 0.625,0.354 false 2.417,0.531 2.521,0.313 2.521,0.313 2.677,0.313 false 0.688,0.271 1,0.427 0.313,0.156 10 false *a 2.719,0.219 3.031,0.375 0.313,0.156 10 false *a

*a	Lock Lever

Detach the claw and raise the lock lever to disconnect the No. 6 engine wire connector as shown in the illustration.

Start the engine. After the engine has stopped on its own, turn the ignition switch off.

NOTICE:: Do not increase the engine speed or drive the vehicle while waiting for the engine to stop on its own.

xi.

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

HINT:: DTC P008700 (Fuel Rail / System Pressure - Too Low) and P017100 (System Too Lean) may be stored. Clear the DTCs before proceeding to the next step.; Click hereEngine / Hybrid System>M20D-FKS (ENGINE CONTROL)>SFI SYSTEM>DTC CHECK / CLEAR201910,202304,_51,_083058,_0401834,RM100000001JDWI,202304,202409,_51,_083058,_0401834,RM1000000029C72,202409,999999,_51,_083058,_0401834,RM100000002NA8O,

xii.

Remove the fuel tank cap assembly and discharge the pressure from the fuel tank sub-assembly.

xiii.

Disconnect the cable from the negative (-) battery terminal.

xiv.

*a	Lock Lever

Connect the No. 6 engine wire connector and push down the lock lever to attach the claw as shown in the illustration.

xv.

Install the No. 2 engine under cover assembly.

xvi.

Install the No. 1 engine under cover.

xvii.

Install the front fender front splash shield LH.

xviii.

Install the front fender front splash shield RH.

xix.

Remove any remaining butyl tape from the rear floor service hole cover and body.

xx.

Connect the connector to the fuel suction with pump and gauge tube assembly.

xxi.

Install the rear floor service hole cover with new butyl tape.

NOTICE:: Securely install the rear floor service hole cover.

xxii.

Install the rear seat cushion lock hook.

for GTMC Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for GTMC Made)>INSTALLATION202004,999999,_58,_083102,_0419060,RM100000001MO2Z_01_0038,

for SFTM Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for SFTM Made)>INSTALLATION202004,999999,_58,_083102,_0419059,RM100000001MO2U_01_0038,

xxiii.

Install the bench type rear seat cushion assembly.

for GTMC Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for GTMC Made)>INSTALLATION202004,999999,_58,_083102,_0419060,RM100000001MO2Z_01_0025,

for SFTM Made:

Click hereVehicle Interior>SEAT>REAR SEAT ASSEMBLY (for SFTM Made)>INSTALLATION202004,999999,_58,_083102,_0419059,RM100000001MO2U_01_0025,

FUEL LINE

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

Discharge fuel system pressure.

ii.

Disconnect the fuel tube.

iii.

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

iv.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

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.

0,0 0,0 false

	Open
	Pull

Clamp Type A (No. 1 Fuel Pipe Clamp):

Open the cover of the No. 1 fuel pipe clamp and remove the No. 1 fuel pipe clamp from the fuel tube connector.

ii.

Clamp Type B (Fuel Pipe Clamp):

Remove the fuel pipe clamp from the fuel tube connector.

iii.

Check that there is no foreign matter around the fuel tube connector before disconnecting it. Clean it if necessary.

iv.

1.833,2.344 2.073,2.031 2.073,2.031 2.219,2.031 false 2.271,1.948 2.583,2.104 0.313,0.156 10 false *a

*a	Retainer
	Retainer Holding Position
	Pull out

While holding the retainer at the positions shown in the illustration, pull up the retainer to disengage the lock claws.

HINT:

1.677,0.698 1.833,0.698 1.833,0.698 2.042,0.99 false 1.833,0.365 1.979,0.365 1.979,0.365 2.323,0.875 false 1.667,0.271 1.979,0.427 0.313,0.156 10 false *a 1.51,0.615 1.823,0.771 0.313,0.156 10 false *b

*a	Retainer
*b	Protective Tape

If the lock claws of the retainer are difficult to disengage, disengage them using a screwdriver with its tip wrapped with protective tape.

1.167,0.354 1.313,0.354 1.313,0.354 1.625,0.646 false 1.896,1.948 2.104,1.573 2.104,1.573 2.25,1.573 false 1.979,3.188 2.073,2.938 2.073,2.938 2.219,2.938 false 1.354,3.333 1.604,3.333 1.604,3.333 1.604,3.594 false 2.125,3.885 2.281,4.302 2.281,4.302 2.396,4.302 false 0.833,4.177 0.833,3.917 true 1.875,4.26 1.875,4.063 false 1.479,3.594 1.479,3.333 false 1,0.26 1.313,0.417 0.313,0.156 10 false *a 1.198,3.24 1.51,3.396 0.313,0.156 10 false *b 1.802,4.292 2.115,4.448 0.313,0.156 10 false *c 0.75,4.208 1.063,4.365 0.313,0.156 10 false *d 2.448,4.208 2.76,4.365 0.313,0.156 10 false *e 2.302,1.49 2.615,1.646 0.313,0.156 10 false *a 2.271,2.854 2.583,3.01 0.313,0.156 10 false *a

*a	Retainer
*b	O-ring
*c	Fuel Tube Connector
*d	Nylon Tube
*e	Fuel Pipe
	Retainer Holding Position
	Pull out
	Pull off

Pull up the retainer while holding it at the positions shown in the illustration and pull off the fuel tube connector.

vi.

If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

NOTICE:: ·

Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

·

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

vii.

Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

viii.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

Quick Type A:

Perform the following procedure when connecting a fuel tube connector.

NOTICE:: Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

1.167,2.354 1.448,2.354 false 1,2.25 1.313,2.406 0.313,0.156 10 false *a

*a	Retainer
	Push
	Push in

Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, and then push in the retainer to secure the connection.

NOTICE:: Confirm that the retainer makes a "click" sound when pushed.

HINT:: If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

ii.

After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

iii.

Clamp Type A (No. 1 Fuel Pipe Clamp):

Install the No. 1 fuel pipe clamp to the fuel tube connector and close the cover of the No. 1 fuel pipe clamp.

iv.

Clamp Type B (Fuel Pipe Clamp):

Install the fuel pipe clamp to the fuel tube connector.

Inspect for fuel leaks.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION201910,999999,_51,_083060,_0403631,RM100000001JU2Y_01_0002,

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.

1.938,2.135 2.198,2.135 false 2.125,3.333 2.25,3.083 2.25,3.083 2.375,3.083 false 1.719,3.24 1.833,3.24 1.833,3.24 1.958,3.656 false 2.302,4 2.417,4.302 2.417,4.302 2.531,4.302 false 2.083,4.281 2.083,4.115 false 2.24,2.063 2.552,2.219 0.313,0.156 10 false *a 2.583,4.229 2.896,4.385 0.313,0.156 10 false *b 1.563,3.167 1.875,3.323 0.313,0.156 10 false *d 2.021,4.302 2.333,4.458 0.313,0.156 10 false *c 2.417,3.01 2.729,3.167 0.313,0.156 10 false *a

*a	Retainer
*b	Fuel Pipe
*c	Fuel Tube Connector
*d	O-ring
	Pull out
	Pull off

Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

ii.

If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

NOTICE:: Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe (fuel pipe).

iii.

Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

iv.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

Quick Type B:

Perform the following procedure when connecting a fuel tube connector.

NOTICE:: Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

1.865,2.26 1.979,2.052 1.979,2.052 2.156,2.052 false 2.198,1.969 2.51,2.125 0.313,0.156 10 false *a

*a	Retainer
	Push
	Push in

Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, and then push in the retainer to secure the connection.

NOTICE:: Confirm that the retainer makes a "click" sound when pushed.

HINT:: If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

ii.

After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

iii.

Inspect for fuel leaks.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION201910,999999,_51,_083060,_0403631,RM100000001JU2Y_01_0002,

Quick Type C:

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.

0.854,3.063 1.073,3.063 1.073,3.063 1.26,2.854 false 2.052,2.75 2.417,2.75 false 0.688,2.979 1,3.135 0.313,0.156 10 false *a 1.885,2.667 2.198,2.823 0.313,0.156 10 false *a

*a	Retainer
	Pull out
	Pull off

Pull out the retainer to disengage the lock claws and pull off the fuel tube connector.

ii.

1.979,1.729 1.979,1.302 false 1.656,1.74 2.135,1.74 2.135,1.74 2.135,1.313 false 2.875,1.729 2.875,1.531 2.875,1.531 2.583,1.25 false 2.542,0.917 2.708,0.49 2.708,0.49 2.802,0.49 false 2.052,0.427 2.219,0.427 2.219,0.427 2.375,0.844 false 2.833,0.396 3.146,0.552 0.313,0.156 10 false *a 1.49,1.646 1.802,1.802 0.313,0.156 10 false *b 1.896,0.333 2.208,0.49 0.313,0.156 10 false *c 2.792,1.75 3.021,1.906 0.229,0.156 10 false *d

*a	Retainer
*b	O-ring
*c	Fuel Tube Connector
*d	Fuel Pipe

If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

NOTICE:: Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).

iii.

Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

iv.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

Quick Type C:

Perform the following procedure when connecting a fuel tube connector.

NOTICE:: Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

0.844,3.094 1.031,3.094 1.031,3.094 1.271,2.844 false 2.021,2.75 2.406,2.75 false 0.677,3 0.99,3.156 0.313,0.156 10 false *a 1.844,2.656 2.156,2.813 0.313,0.156 10 false *a

*a	Retainer
	Push
	Push in

Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, and then push in the retainer to secure the connection.

NOTICE:: Confirm that the retainer makes a "click" sound when pushed.

HINT:: If it is difficult to push the fuel tube connector onto the fuel pipe, apply a small amount of clean gasoline to the tip of the fuel pipe.

ii.

After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

iii.

Inspect for fuel leaks.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION201910,999999,_51,_083060,_0403631,RM100000001JU2Y_01_0002,

Quick Type D:

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.

2,2.823 2.167,3.021 2.167,3.021 2.281,3.021 false 1.385,3.208 1.573,3.208 1.573,3.208 1.677,3.458 false 1.448,4.469 1.448,4.146 false 1.302,4.469 1.521,4.469 1.521,4.469 1.521,4.146 false 2.469,4.385 2.344,4.385 2.344,4.385 2.219,4.167 false 1.938,1.99 1.938,1.208 true 2.333,2.938 2.646,3.094 0.313,0.156 10 false *a 1.146,4.385 1.458,4.542 0.313,0.156 10 false *b 1.229,3.115 1.542,3.271 0.313,0.156 10 false *c 2.531,4.313 2.844,4.469 0.313,0.156 10 false *d 1.854,2 2.167,2.156 0.313,0.156 10 false *e

*a	Retainer
*b	O-ring
*c	Fuel Tube Connector
*d	Fuel Tank Assembly
*e	Claw
	Push
	Push
	Pull off

Push the claw of the retainer, push the retainer of fuel tube connector, and then pull the fuel tube connector off of the fuel tank assembly.

NOTICE:: Be sure to disconnect the fuel tube connector by hand.

ii.

If the fuel tube connector and fuel tank assembly are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel tank assembly carefully.

NOTICE:: ·

Be sure to disconnect the fuel tube connector by hand.

·

Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel tank assembly).

iii.

Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

iv.

Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

Quick Type D:

Perform the following procedure when connecting a fuel tube connector.

NOTICE:: Check that there is no damage or foreign matter on the connecting parts of the fuel lines.

1.708,0.292 1.823,0.292 1.823,0.292 1.969,0.74 false 1.542,0.198 1.854,0.354 0.313,0.156 10 false *a

*a	Retainer
	Pull out

Pull out the retainer until the retainer makes a "click" sound.

ii.

2.104,2.99 2.188,3.208 2.188,3.208 2.333,3.208 true 2.396,3.125 2.708,3.281 0.313,0.156 10 false *a

*a	Retainer
	Push
	Push in

Align the fuel tube connector with the fuel tank assembly, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean gasoline to the tip of the fuel pipe and reinsert it.

iii.

Connect the fuel lines and push in the retainer. Check that the fuel tube connector is securely connected by pulling on it.

iv.

Inspect for fuel leaks.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION201910,999999,_51,_083060,_0403631,RM100000001JU2Y_01_0002,

FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY

NOTICE:

2.031,1.271 2.615,0.958 2.615,0.958 2.854,0.958 true 2.885,0.865 3.198,1.063 0.313,0.198 10 false *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 sub-tank sub-assembly.

INSPECT FOR FUEL LEAK

Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION201910,999999,_51,_083060,_0403631,RM100000001JU2Y_01_0002,