RM38N0EC _51 Engine / Hybrid System _111793 M20C-FKS, M20D-FKS FUEL _0504174 FUEL SYSTEM L

M20C-FKS, M20D-FKS FUEL  FUEL SYSTEM  PRECAUTION  


CAUTION:
·
A360563

Never perform work on fuel system components near any possible ignition sources.

·

Vaporized fuel could ignite, resulting in a serious accident.

·
A360564

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.

·
A344817

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.

·
A357489

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


a.

Before inspecting and repairing the fuel system, disconnect the cable from the negative (-) battery terminal.

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS BATTERY>REMOVAL


b.

Do not smoke or work near fire when handling the fuel system.


c.

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.



a.

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

i.

Remove the rear floor service hole cover.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL PUMP>REMOVAL


ii.
A576254

Disconnect the fuel pump connector.


iii.
A467780

Disconnect the fuel pump assembly connector.


iv.

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.



v.

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

HINT:

DTC P008700 (Fuel Rail / System Pressure - Too Low) or P017100 (System Too Lean Bank 1) may be stored. Clear the DTCs before proceeding to the next step.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>SFI SYSTEM>DTC CHECK / CLEAR



vi.

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

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS BATTERY>REMOVAL


vii.

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


viii.

Connect the fuel pump assembly connector.


ix.

Connect the fuel pump connector.


x.

Install the rear floor service hole cover.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL PUMP>INSTALLATION




FUEL LINE


a.

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

i.

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.



b.

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.


i.
A463653C01
0,0 0,0 false
V100135

Open
V100136

Pull


Clamp Type A (EFI Fuel Pipe Clamp):

Open the cover of the EFI fuel pipe clamp and remove the EFI fuel pipe clamp from the fuel tube connector.


ii.
A443068

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.
A428378C01
1.833,2.354 2.188,2.021 2.188,2.021 2.271,2.021 false 1.156,0.615 1.26,0.615 1.26,0.615 1.656,0.948 false 2.344,1.927 2.573,2.125 0.229,0.198 10 false *a 0.948,0.521 1.177,0.719 0.229,0.198 10 false *a
*a Retainer
V100135

Retainer Holding Position
V100136

Pull out


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


v.
A438412C01
1.167,0.333 1.25,0.333 1.25,0.333 1.615,0.625 false 1.917,1.969 2.25,1.708 2.25,1.708 2.333,1.708 false 2.135,3.604 2.469,3.188 2.469,3.188 2.552,3.188 false 1.354,3.25 1.604,3.25 1.604,3.25 1.604,3.583 true 1.49,3.583 1.49,3.25 true 2,4.073 2.167,4.323 2.167,4.323 2.25,4.323 false 0.75,3.896 1.083,4.313 1.083,4.313 1.167,4.313 true 0.958,0.24 1.271,0.438 0.313,0.198 10 false *a 2.448,1.646 2.76,1.844 0.313,0.198 10 false *a 2.635,3.094 2.948,3.292 0.313,0.198 10 false *b 2.344,4.24 2.656,4.438 0.313,0.198 10 false *c 1.135,3.167 1.448,3.365 0.313,0.198 10 false *d 1.271,4.229 1.583,4.427 0.313,0.198 10 false *e
*a Retainer
*b Fuel Pipe
*c Fuel Tube Connector
*d O-ring
*e Nylon Tube
V100135

Retainer Holding Position
V100136

Pull out
V100137

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.



c.

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.


i.
A428381C01
1.25,0.615 1.333,0.615 1.333,0.615 1.667,0.948 false 1.906,2.333 2.24,2.083 2.24,2.083 2.323,2.083 false 1.031,0.531 1.344,0.729 0.313,0.198 10 false *a 2.396,2 2.708,2.198 0.313,0.198 10 false *a
*a Retainer
V100135

Push
V100136

Push in


Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, 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 (EFI Fuel Pipe Clamp):

Install the EFI fuel pipe clamp to the fuel tube connector and close the cover of the EFI fuel pipe clamp.


iv.

Clamp Type B (Fuel Pipe Clamp):

Install the fuel pipe clamp to the fuel tube connector.


v.

Inspect for fuel leaks.

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION



d.

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.


i.
A428489C01
1.125,2.729 1.281,2.729 1.281,2.729 1.5,2.469 true 0.833,3.281 0.969,3.281 0.969,3.281 1.104,3.594 false 1.927,2.115 1.927,1.865 false 1.625,4.219 1.625,3.896 false 2.865,3.656 2.917,3.344 2.917,3.344 3.031,3.344 false 1.792,3.906 1.792,4.219 1.792,4.219 1.5,4.219 false 1.896,0.552 2.417,0.167 2.417,0.167 2.531,0.167 true 1.521,2.115 1.521,1.865 1.521,1.865 2.104,1.865 false 2.49,4.042 2.594,4.365 2.594,4.365 2.708,4.365 false 3.125,3.281 3.375,3.51 0.25,0.229 10 false *b 2.781,4.281 3.094,4.438 0.313,0.156 10 false *c 1.302,4.167 1.615,4.323 0.313,0.156 10 false *d 0.927,2.646 1.24,2.802 0.313,0.156 10 false *a 2.198,1.781 2.375,1.958 0.177,0.177 10 false *e 0.677,3.219 0.854,3.396 0.177,0.177 10 false *f 2.625,0.094 2.938,0.25 0.313,0.156 10 false *a
*a Retainer
*b Fuel Pipe
*c Fuel Tube Connector
*d O-ring
*e Claw
*f Nylon Tube
V100135

Push
V100136

Pull out
V100137

Pull off


Disengage the 2 claws of the retainer. Pull out the retainer and pull off the fuel tube connector.

NOTICE:

Be sure to disconnect the fuel tube connector by hand.



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:
·

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 pipe).

·

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




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.



e.

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.


i.
A428490C01
1.781,2.75 2.094,2.75 false 1.854,0.615 2.198,0.802 2.198,0.802 2.313,0.802 true 1.833,1.896 1.833,2.313 false 1.438,2.313 1.438,1.896 1.438,1.896 2.198,1.896 false 2.198,2.667 2.51,2.823 0.313,0.156 10 false *a 2.281,1.813 2.594,1.969 0.313,0.156 10 false *b 2.417,0.708 2.729,0.865 0.313,0.156 10 false *a
*a Retainer
*b Claw
V100135

Push
V100136

Push in


Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to engage the 2 claws.

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>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION



f.

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.


i.
A428718C01
2.094,2.323 1.958,2.146 1.958,2.146 1.74,2.146 false 2.021,2.948 1.875,3.104 1.875,3.104 1.646,3.104 true 1.969,3.656 1.969,3.25 1.969,3.25 1.708,3.25 true 2.823,3.104 2.656,3.104 2.656,3.104 2.542,2.948 true 2.5,0.594 2.302,0.594 2.302,0.594 1.979,0.896 false 2.865,4.375 2.729,4.375 2.729,4.375 2.615,4.021 false 2.031,4.125 2.031,4.365 false 1.552,2.052 1.865,2.208 0.313,0.156 10 false *a 2.917,4.302 3.229,4.458 0.313,0.156 10 false *b 1.958,4.375 2.271,4.531 0.313,0.156 10 false *c 1.542,3.188 1.854,3.344 0.313,0.156 10 false *d 1.479,3.01 1.792,3.167 0.313,0.156 10 false *e 2.594,0.521 2.906,0.677 0.313,0.156 10 false *a 2.875,3.021 3.188,3.177 0.313,0.156 10 false *e
*a Retainer
*b Fuel Pipe
*c Fuel Tube Connector
*d O-ring
*e Claw
V100135

Pull
V100136

Pull out
V100137

Pull off


Disengage the 2 claws of the retainer. Pull out the retainer and pull off the fuel tube connector.

NOTICE:

Be sure to disconnect the fuel tube connector by hand.



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:
·

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 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.



g.

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.


i.
A428719C01
2.271,3 2.427,3 2.427,3 2.531,2.865 true 2.198,2.406 2.427,2.406 false 2.927,2.865 3.042,3.01 3.042,3.01 3.198,3.01 true 1.958,0.99 2.229,0.625 2.229,0.625 2.385,0.625 true 2.01,2.313 2.323,2.469 0.313,0.156 10 false *a 2.063,2.917 2.375,3.073 0.313,0.156 10 false *b 3.25,2.938 3.427,3.135 0.177,0.198 10 false *b 2.49,0.552 2.802,0.708 0.313,0.156 10 false *a
*a Retainer
*b Claw
V100135

Push
V100136

Push in


Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, then push in the retainer to engage the 2 claws.

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>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION



h.

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.


i.
A444691C01
2.083,3.542 1.781,3.24 1.781,3.24 1.646,3.24 false 1.646,4.375 2.021,4.375 2.021,4.375 2.021,4 true 2.604,3.948 2.729,4.344 2.729,4.344 2.917,4.344 false 2.021,1.104 2.219,1.479 2.219,1.479 2.365,1.479 false 1.771,2.333 2.094,2.135 2.094,2.135 2.24,2.135 false 1.896,4.365 1.896,4 true 2.448,1.396 2.76,1.594 0.313,0.198 10 false *a 2.99,4.26 3.302,4.458 0.313,0.198 10 false *b 1.448,4.292 1.76,4.49 0.313,0.198 10 false *d 1.448,3.156 1.76,3.354 0.313,0.198 10 false *c 2.333,2.052 2.646,2.25 0.313,0.198 10 false *a
*a Retainer
*b Fuel Pipe
*c Fuel Tube Connector
*d O-ring
V100135

Pull out
V100136

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 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.



i.

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.


i.
A428905C01
1.073,2.552 1.458,2.552 false 2.021,1.115 2.354,1.448 2.354,1.448 2.521,1.448 false 0.854,2.469 1.167,2.667 0.313,0.198 10 false *a 2.594,1.354 2.906,1.552 0.313,0.198 10 false *a
*a Retainer
V100135

Push
V100136

Push in


Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, 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>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION



j.

Quick Type E:

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.


i.
A420295C01
1.896,2.396 2.146,2.146 2.146,2.146 2.313,2.146 true 1.552,3.417 1.969,3.417 1.969,3.417 1.969,3.75 true 1.885,3.75 1.885,3.417 true 2.375,4.271 2.458,4.438 2.458,4.438 2.625,4.438 false 2,4.521 2.167,4.521 2.167,4.521 2.167,4.396 false 0.594,0.552 0.76,0.552 0.76,0.552 1.323,0.75 true 2.396,2.073 2.708,2.271 0.313,0.198 10 false *a 2.698,4.365 3.01,4.563 0.313,0.198 10 false *b 1.375,3.354 1.688,3.552 0.313,0.198 10 false *d 1.802,4.448 2.115,4.646 0.313,0.198 10 false *c 0.365,0.479 0.677,0.677 0.313,0.198 10 false *a
*a Retainer
*b Fuel Pipe
*c Fuel Tube Connector
*d O-ring
V100135

Pull out
V100136

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 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.



k.

Quick Type E:

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.


i.
A420296C01
2.01,2.448 2.292,2.177 2.292,2.177 2.458,2.177 false 0.583,0.625 0.75,0.625 0.75,0.625 1.354,0.896 true 2.552,2.104 2.865,2.302 0.313,0.198 10 false *a 0.375,0.531 0.688,0.729 0.313,0.198 10 false *a
*a Retainer
V100135

Push
V100136

Push in


Align the fuel tube connector with the fuel pipe, push the fuel tube connector onto the fuel pipe, 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>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION




FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY


NOTICE:
A448347C01
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
*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.



INSPECT FOR FUEL LEAK


a.

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION