Fuel System: Precaution
2GR-FE FUEL: FUEL SYSTEM: PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM
(a) When disconnecting a fuel line, fuel will splash. So observe the following precautions:
(1) Do not smoke or work near fire when handling the fuel system.
(2) Keep gasoline away from rubber or leather parts.
2. DISCHARGE FUEL SYSTEM PRESSURE
CAUTION:
* Perform the following procedure to prevent fuel from spilling out 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 shop rag or a piece of cloth to prevent fuel from spraying or coming out.
(a) Remove the rear seat cushion assembly Removal.
(b) Remove the rear seat cushion lock hook Removal.
(c) Remove the rear floor service hole cover.
(d) Disconnect the fuel pump connector.
(e) Start the engine.
(f) After the engine has stopped on its own, turn the engine switch off.
(g) Crank the engine again and make sure that the engine does not start.
HINT
DTC P0171/74 (fuel problem) may be stored.
(h) Disconnect the cable from the negative (-) battery terminal.
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
(i) Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.
(j) Connect the fuel pump connector.
(k) Install the rear floor service hole cover with new butyl tape.
(l) Install a new rear seat cushion lock hook Installation.
(m) Install the rear seat cushion assembly Installation.
3. FUEL LINE
(a) When disconnecting a high pressure fuel line, a large amount of gasoline will spill out, so perform the following procedure:
(1) Discharge fuel system pressure (Step 2).
(2) Disconnect the fuel pump tube.
(3) Drain the fuel that remains in the fuel pump tube.
(4) Cover the disconnected fuel pump tube with a plastic bag to prevent damage and contamination.
(5) Put a container under the connectors.
(b) Perform the following procedure when disconnecting the fuel tube connector (quick type A):
(1) Remove the fuel pipe clamp.
Text in Illustration
(2) Check that there is no dirt or other foreign matter on the fuel pipe and contact surface before disconnecting them. Clean them if necessary.
(3) Disconnect the fuel tube connector from the fuel pipe by hand.
(4) If the fuel tube connector and the fuel pipe are stuck, push in and pull on the fuel tube connector to release them. Pull the fuel tube connector out of the fuel pipe carefully.
Text in Illustration
(5) Check that there is no dirt or other foreign matter on the contact surface of the disconnected fuel pipe. Clean them away if necessary.
(6) Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
(c) Perform the following procedure when connecting a fuel tube connector (quick type A):
(1) Check if there is any damage or foreign matter on the fuel pipe connections.
(2) Match the axis of the fuel tube connector with the axis of the fuel pipe, and push the fuel pipe into the fuel tube connector 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 engine oil to the tip of the fuel pipe.
(3) After connecting, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
(4) Inspect for fuel leaks Fuel System.
(5) Install the fuel pipe clamp.
(d) Perform the following procedure when disconnecting a fuel tube connector (quick type B):
Text in Illustration
(1) Check that there is no damage or foreign matter on the part of the fuel pipe that contacts the fuel tube connector.
(2) Detach the 2 claws of the fuel tube connector retainer. Push down on the fuel tube connector and disconnect it from the fuel pipe.
HINT
Be sure to disconnect it by hand.
(3) If the fuel tube connector and fuel pipe are stuck, pinch the fuel pipe by hand and push or pull the fuel tube connector to disconnect it.
(4) Check for foreign matter on the seal surface of the disconnected fuel pipe. Clean it if necessary.
(5) Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.
(e) Perform the following procedure when connecting a fuel tube connector (quick type B):
(1) Line up the two parts of the fuel pipes to be connected, and fully push the fuel tube connector and fuel pipe together until they are fully seated. Next, push the retainer into the fuel tube connector until its claws lock. If the fuel pipe is difficult to push into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.
(2) After connecting the fuel pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.
(3) Inspect for fuel leaks Fuel System.
(f) Observe the following precautions when handling a nylon tube:
CAUTION:
* Do not twist the fuel tube connector part of the nylon tube or the fuel tube connector when connecting them.
* Do not remove the EPDM protector on the outside of the nylon tube.
* Do not pinch or kink the nylon tubes to prevent fuel leakage.
4. INJECTOR
(a) Install the injector to the delivery pipe and the lower intake manifold as shown in the illustration.
Text in Illustration
NOTICE:
Before installing the injector, be sure to apply appropriate lubricant or gasoline where the delivery pipe or intake manifold contacts the injector O-rings.
(b) Observe the following precautions when removing and installing the fuel injectors:
Text in Illustration
(1) Do not reuse the O-ring and insulator.
(2) When placing a new O-ring on the injector, do not damage the O-ring.
(3) Coat a new O-ring with spindle oil or gasoline before installing it.
NOTICE:
Do not use engine oil, gear oil or brake fluid.
5. FUEL SUCTION TUBE WITH PUMP AND GAUGE ASSEMBLY
(a) 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 welded to the plate.
Text in Illustration
6. INSPECT FOR FUEL LEAK
(a) Check that there are no fuel leaks after performing maintenance anywhere on the fuel system Fuel System.