QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[ZJ, ZY, Z6]

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Warning

• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE PRECAUTION”.

Quick Release Connector Type

Caution

• There are four types of quick release connectors. Verify the type and location, and install/remove properly.

Without the fuel filter (high-pressure)

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With the fuel filter (high-pressure)

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Type A Removal

1. Follow “BEFORE SERVICE PRECAUTION” before performing any work operations to prevent fuel from spilling from the fuel system.

Caution

• The quick release connector may be damaged if the release tab is bent excessively. Do not expand the release tab over the stopper.

Note

• The fuel hose can be removed by pushing it to the pipe side to release the lock.

2. Rotate the release tab on the quick release connector to the stopper position.

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3. Pull out the fuel hose straight from the fuel pipe and disconnect it.

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4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

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Type B Removal

Caution

• Be careful not to damage the pipe when unlocking the retainer.

Note

• When a prompt connector is detached, following SST can be used.

― 49 N013 103A

― 49 E042 001

When using SST 49 N013 103A

1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations. (See BEFORE SERVICE PRECAUTION[ZJ, ZY, Z6].)

2. Verify that the quick release connector joint area is free of foreign material. Clean if necessary.

3. Install the SST as shown in the figure and push into the quick release connector to disconnect the fuel pipe.

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4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.

When using SST 49 E042 001

Note

• If the quick release connector is removed, replace the retainer with a new one.

1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations.(See BEFORE SERVICE PRECAUTION[ZJ, ZY, Z6].)

2. Set the SST parallel to the quick release connector.

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Note

• The quick release connector can be removed by pushing the center of the retainer tabs.

• The retainer is attached to the pipe even after the connector is disconnected.

3. Hold the center of the retainer tabs with the SST ends and press the retainer.

4. Pull the connector side and disconnect the quick release connector.

5. Raise a retainer tab using the SST and remove the retainer.

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6. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

Type C Removal

1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations.

2. Push the release tab on the retainer to unlock.

Without the fuel filter (high-pressure)

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With the fuel filter (high-pressure)

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3. Pull out the fuel hose straight from the fuel pipe and disconnect it.

4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

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Type D Removal

1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing any work operations.

2. Move the retainer upward using a small flathead screwdriver or a similar tool.

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3. Pull out the fuel hose straight from the fuel pipe and disconnect it.

4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

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Type A Installation

Note

• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

• A checker tab is integrated with the quick release connector for new fuel hoses and evaporative hoses. Remove the checker tab from the quick release connector after the connector is completely engaged with the fuel pipe.

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1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

• If there is any malfunction, replace it with a new one.

2. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.

3. Reconnect the fuel hose straight to the fuel pipe until a click is heard.

Note

• If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or has not slipped, and then reconnect the quick release connector.

4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0—3.0 mm {0.08—0.12 in} and is connected securely.

5. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”.

Type B Installation

Note

• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

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Using the SST

1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

• If there is any malfunction, replace it with a new one.

2. Reconnect the fuel hose straight to the fuel pipe until a click is heard.

3. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

4. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”.

Without using the SST

Caution

• Be sure to replace the retainer with a new one to prevent gas leakage.

• To prevent evaporative gas leakage, be sure not to damage the connecting part between the charcoal canister and pipe, and the locks between the quick release connector and retainer. If any of them are damaged, replace the charcoal canister or hose with a new one.

1. Remove the retainer remaining on the charcoal canister pipe.

2. Install a new retainer to the quick release connector.

3. Reconnect the hose straight to the pipe until a click is heard.

4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

5. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”.

Type C Installation

Note

• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

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1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

• If there is any malfunction, replace it with a new one.

2. When disconnecting and reconnecting the quick release connector, verify if the metal reinforcement pipe protrudes from the resin pipe end while pressing the end with a finger.

• If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe.

3. Reconnect the fuel hose straight to the fuel pipe until a click is heard.

4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

5. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”.

Type D Installation

Note

• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.

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1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.

• If there is any malfunction, replace it with a new one.

2. When disconnecting and reconnecting the quick release connector, verify if the metal reinforcement pipe protrudes from the resin pipe end while pressing the end with a finger.

• If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe.

3. Insert the fuel pipe straight to the end of the quick release connector.

4. Push down the retainer using a finger.

• If the retainer cannot be pushed down, push the fuel pipe further to the quick release connector.

5. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

6. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”.