Fuel System Safety Procedures

GENERAL PRECAUTION

1. Before working on the fuel system, disconnect the cable from the Negative terminal (-) of the Battery.

HINT: Any Diagnostic Trouble Code retained by the Engine Control Module will be erased when the Battery terminal is removed.

Therefore, if necessary. read the diagnostic codes before removing the Battery terminal.

2. Do not smoke or work near an open flame when working on the fuel system.

3. Keep gasoline off rubber or leather parts.


FUEL SYSTEM

1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out. so observe the following procedure.






a. Put a container under the connection. Cover the connection with a rag, if possible.

b. Slowly loosen the connection.

c. Disconnect the connection.

d. Plug the connection with a rubber plug.

2. When connecting the flare nut or union bolt on the high pressure pipe union observe the following procedure:

Union bolt type:






a. Always use a new gasket.

b. Tighten the union bolt by hand.

c. Tighten the bolt to the specified torque.


Flare nut type:

a. Apply a light coat of oil on the flare and tighten the flare nut by hand.






b. Using SST, tighten the flare nut to the specified torque. (SST 09631-22020)

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

3. Observe the following precautions when removing and installing the Injectors.

a. Never reuse an O-ring.

b. When placing a new O-ring on the Injector, take care not to damage it in any way.

c. Coat the new O-rings with spindle oil or gasoline before installing never use engine, gear or brake oil.











4. Install the Injector in the Delivery Pipe and Cylinder Head as shown in the illustration.

5. Check for fuel leaks after performing any maintenance on the fuel system.

a. With engine stopped. turn the Ignition Switch ON.






b. Using SST, connect terminals +B and FP of the Data Link Connector 1. (SST 09843-18020)






c. When the fuel return hose is pinched. the pressure within the high pressure line will rise to about 392 kPa (57 psi). In this state, check to make sure that there are no leaks from any part of the fuel system.

NOTE: Always pinch the hose. Avoid bending it as it may cause the hose to crack.






d. Remove the SST. (SST 09843-18020)