- Safety is the most important factor when performing not only fuel system maintenance, but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines.
- To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied.
- Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts.
- Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container.
- Always keep a dry chemical (Class B) fire extinguisher near the work area.
- Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.
- Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping.
- Always replace worn fuel fitting O-rings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.
- Before servicing the vehicle, make sure to refer to the precautions in the beginning of this section as well.
WARNING
Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
Fastener Notice:
- Use the correct fastener in the correct location.
- Replacement fasteners must be the correct part number for that application.
- Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure.
- Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener.
- Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Service Precaution for Fuel System/Gasoline/Gasoline Vapors:
CAUTION
Always install new injector O-rings when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil
CAUTION
If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system.
WARNING
Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury:
- Keep a dry chemical (Class B) fire extinguisher near the work area.
- Place a "CAUTION FLAMMABLE" sign in the work area.
- Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away.
- Wear eye protection.
- Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537 degrees C (1000 degrees F).
- Relieve the fuel system pressure prior to disconnecting fuel system components.
- Disconnect the negative battery cable except for tests where battery voltage is required.
- Use a suitable container to store or catch fuel.
- Do not replace fuel pipe with fuel hose.
- Plug all disconnected fuel line fittings and hoses.
- After making any fuel system repairs ALWAYS inspect for fuel leaks.
CAUTION
Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.
CAUTION
Whenever fuel lines are removed, place fuel in an approved container. Container opening must be a minimum of 300 mm (12 in.) diameter to adequately catch fuel.
WARNING
Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.
WARNING
Any time the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
WARNING
Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.
- Anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
- Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around fitting while connecting gauge, to collect fuel. Place the cloth in an approved container.
WARNING
Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.
CAUTION
When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures.
- Work carefully to prevent gasoline spillage
- Disconnect the main fuel line
- Drain the fuel remaining inside the fuel line
- Protect the disconnected fuel line(s) from damage and foreign material by covering connection ends with a vinyl bag
Note: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
- The fuel pipe connections
- The hose connections
- The areas surrounding the connections
WARNING
Wrap a shop towel around the fuel pressure connection to avoid spillage and in order to reduce the risk of fire and personal injury.
- The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage.
- Place the towel in an approved container when the connection is complete.
- Never store the fuel (or fuel coated items) in an open container due to the possibility of a fire or an explosion
WARNING
Do not allow smoking or use of open flames in area where work on fuel system is taking place.
- Anytime work is being done on fuel system, disconnect negative battery cable, except for those tests where battery voltage is required.
- Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.
Note: Check that there is no dirt or mud on the pipe and around the fuel connectors before disconnecting them.
- Be careful of mud and dirt because the fuel tube connector has an O-ring to seal the fuel tube connector and pipe.
- Do not use any tools for this operation.
- Do not bend or twist the nylon tube by force.
- After disconnecting, cover the fuel tube connector with a vinyl bag.
- When the fuel tube connector and line are stuck, pinch the fuel emission tube between your fingers, and turn it carefully to free and disconnect the fuel emission tube.