FUEL SYSTEM > PRECAUTION

for Preparation Click here

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

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

3. Keep gasoline away from rubber or leather parts.
   

NOTICE:

1. Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
   

1. Even after discharging the fuel pressure, place a shop rag or a piece of cloth over the fittings to prevent fuel from splashing on yourself or in the engine compartment when separating the fittings.
   

1. When using the intelligent tester:
   
   

   1. Connect the intelligent tester to the DLC3.
      

   2. Put the vehicle in the "inspection mode". (Click here)
      

   3. Start the engine.
      

   4. Turn the tester on.
      

   5. Enter the following menus: Power train / Engine / Active Test.
      

   6. Perform the Active Test by referring to the table below.
      

      Intelligent Tester Displays	Test Details	Control Ranges
      Control the Fuel Pump / Speed (Fuel Pump / Spd)	Activate fuel pump (C/OPN Relay)	ON/OFF

   7. Turn the fuel pump (C/OPN relay) off.
      

   8. Turn the ignition switch off immediately after the engine comes to a "rough idle state".
      

      NOTICE:

      The hybrid system has a complicated process from "out of gas" to "engine stall". Therefore, "rough idle" is regarded as "stop".

      HINT:

      DTCs P0171/25 and P0174/25 indicating LEAN errors may be detected.





2. When not using the intelligent tester (using C/OPN RLY):
   
   

   1. Disconnect the relay block No.3.
      

   2. Remove the junction block cover No.2.
      

   
   
   

   3. Remove the C/OPN RLY.
      

   4. Put the vehicle in the "inspection mode". (Click here)
      

   5. Start the engine.
      

   6. Turn the ignition switch off immediately after the engine comes to a "rough idle state".
      

      NOTICE:

      The hybrid system has a complicated process from "out of gas" to "engine stall". Therefore, "rough idle" is regarded as "stop".

      HINT:

      DTCs P0171/25 and P0174/25 indicating LEAN errors may be detected.

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

   8. Install the C/OPN RLY.
      

1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe the following procedures:
   
   

   1. Discharge the fuel system pressure. (Step 2)
      

   2. Disconnect the fuel tube.
      

   3. Drain the fuel that remains inside the fuel tube.
      

   
   
   

   4. Cover the disconnected fuel tubes with a plastic bag to prevent damage and foreign objects from entering the fuel line.
      

   5. Place a tray under the vehicle or connecting part to catch any fuel that may spill.
      





2. Observe the following precautions when removing and installing the fuel injectors:
   
   

   1. Never reuse the O-rings.
      

   2. When placing a new O-ring on the injector, do not damage the O-ring.
      

   3. Coat new O-rings with grease or gasoline before installation. Do not use engine oil, gear oil or brake fluid.
      





3. Install the injector with the delivery pipe to the cylinder head as shown in the illustration.
   

   NOTICE:

   Before installing the injector, be sure to apply grease or gasoline where the delivery pipe or cylinder head contacts the O-ring of the injector.





4. Observe the following precautions when disconnecting the fuel tube connector (Quick Type A):
   
   

   1. Check for dirt in the pipe around the connector before disconnecting. Clean away the dirt as necessary.
      

   2. Be sure to disconnect the connectors by hand.
      

   3. When the connector and the pipe are stuck, pinch the fuel pipe with your fingers, and push and pull the connector. Disconnect and pull the connector out of the pipe. Do not use any tools.
      

   4. Check for dirt or other foreign objects on the surface of the seal on the disconnected pipe and clean as necessary.
      

   5. Do not damage the disconnected pipe and connector. Cover the disconnected pipe and connector to prevent intrusion of foreign objects.
      





5. Observe the following precautions when connecting the fuel tube connector (Quick Type A):
   
   

   1. Check for 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. If the connection is excessively tight, apply a small amount of fresh engine oil to the tip of the pipe.
      

   
   
   

   3. After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.
      





6. Observe the following precautions when disconnecting the fuel tube connector (Quick Type B):
   
   

   1. Check for dirt in the pipe around the connector before disconnecting. Clean away the dirt as necessary.
      

   2. Be sure to disconnect the connectors by hand.
      

   3. Pinch the tabs of the retainer of the fuel tube connector to disengage the claws and push the retainer down as shown in the illustration.
      

   4. When the connector and the pipe are stuck, pinch the fuel pipe with your fingers, and push and pull the connector. Disconnect and pull it out of the pipe. Do not use any tools.
      

   5. Check for dirt or other foreign objects on the surface of the seal on the disconnected pipe and clean as necessary.
      

   6. Do not damage the disconnected pipe and connector. Cover the disconnected pipe and connector to prevent intrusion of foreign objects.
      





7. Observe the following precautions when connecting the fuel tube connector (Quick Type B):
   
   

   1. Check for 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 in the fuel tube connector until it comes into contact with the seat. Then push in the retainer until the claws lock. If the connection is excessively tight, apply a small amount of fresh engine oil to the tip of the pipe.
      

   
   
   

   3. After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.
      





8. Observe the following precautions when disconnecting the fuel tube connector (Quick Type C):
   
   

   1. Check if there is any dirt in the pipe around the connector before disconnecting them and clean the dirt away as necessary.
      

   2. Be sure to disconnect them by hand.
      

   3. When the connector and the pipe are stuck, pinch the fuel pipe with both hands, and push and pull the connector. Disconnect and pull it out. Do not use any tool at this time.
      

   4. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away as necessary.
      

   5. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
      





9. Observe the following precautions when connecting the fuel tube connector. (Quick Type C):
   
   

   1. Check for 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. If the connection is excessively tight, apply a small amount of fresh engine oil to the tip of the pipe.
      

   
   
   

   3. After finishing the connection, check that the pipe and the connector are securely connected by pulling on them.
      

1. Check that there are no fuel leaks anywhere in the fuel system after performing maintenance (Click here).