Fuel Pressure Release: Service and Repair

FUEL SYSTEM

1. PRECAUTION
a. Before working on fuel system, disconnect the negative (-) terminal cable from the battery.
b. Do not smoke or work near fire when working on fuel system.
c. Keep gasoline away from rubber or leather carts.

2. WORK FOR PREVENT GASOLINE FROM SPILLING OUT

CAUTION:
- Perform disconnecting operation of the fuel system parts after working for prevent gasoline from spilling out.
- As there is remained pressure in the fuel line after working for prevent gasoline from spilling out, prevent it from splashing inside the vehicle compartment by covering them with a shop rag.




a. Remove the circuit opening relay from the engine room relay block.
b. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.

HINT: There is a case that DTC P0171 (system to lean) is output.

c. Check that the engine does not start.
d. Remove the fuel tank cap, and let the air out of the fuel tank.
e. Disconnect the negative (-) terminal cable from the battery.
f. Reinstall the circuit opening relay.

3. FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures.
1. Disconnect the fuel pump tube.
2. Drain the fuel remained inside the fuel pump tube.




3. In order to prevent the disconnected fuel pump tube from damaging and foreign objects being mixed into, cover them with a vinyl bag.
4. Put a container under the connection.




b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union, observe these procedures:
1. Always use new gaskets
2. Tighten the union bolt by your hand.




3. Using SST, tighten the union bolt to the specified torque

SST 09612-24014 (09617-24011)

Torque:
33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST
39 N.m (400 kgf.cm, 29 ft.lbf)

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




c. Observe these precautions when removing and installing the injectors.
1. Never reuse the O-ring
2. When placing new O-ring on the injector, do not damage the O-ring
3. Coat the new O-ring with spindle oil or gasoline before installing Do not use engine oil, gear oil and brake oil.




d. Install the injector to the delivery pipe and lower intake manifold, as shown in the illustration.

NOTE: Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold contacts the O-ring of the injector.




e. Observe these precautions when disconnecting the fuel tube connector (Quick type A):
1. Remove the fuel pipe clamp No 1.




2. Check that there is no dirt like mud on the pipe and around the connector before disconnecting them. Clean them if necessary.
3. Disconnect them by hand.
4. When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe.
5. Inspect that there is no dirt or the like on the seal surface of the disconnected pipe. Clean it away if necessary.
6. In order to prevent the disconnected pipe and connector from damaging and foreign objects being mixed into, cover them with a vinyl bag.




f. Observe these precautions when connecting the fuel tube connector (Quick Type A):
1. Check that there is any damage or foreign objects in the connected part of the pipe.
2. Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. In case that the connection is tight, apply little amount of fresh engine oil on the tip of the pipe.
3. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.




4. Check for any fuel leak.

g. Observe these precautions when disconnecting the fuel tube connector (Quick type B):
1. Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away.
2. Disconnect by your hands.




3. When the connector and the pipe are stuck, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time.
4. Inspect if there is any dirt or the like on the seal surface of the disconnected pipe. Clean it away if necessary.
5. Prevent the disconnected pipe and connector from damaging and foreign objects being mixed into by covering them with a vinyl bag.




h. Observe these precautions when connecting the fuel tube connector (Quick type B):
1. Match the axis of the connector with axis of the pipe, and push in the connector until the connector makes a "click" sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe.
2. After having finished the connection, check if the pipe and the connector are securely connected by pulling them.




3. Check for fuel leakage.

i. Observe these precautions when handling nylon tube.

CAUTION:
- Be careful not to turn the connection part of the nylon tube and the quick connector by force when connecting them.
- Do not kink the nylon tube.
- Do not remove the EPDM protector on the outside of the nylon tube.
- Do not close the piping with the nylon tube by bending it.

4. CHECK FUEL LEAK
a. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.