Fuel system (FA20)
Precautions Parts location System information Removal / installation
FUEL
FUEL SYSTEM (FA20)
PRECAUTIONS
1. Precautions before work
(1) Before performing the work related to the fuel system, perform the fuel spill prevention procedure and disconnect the negative terminal from the battery. (Refer to 
)
)(2) Be sure not to perform the work related to the fuel system near open flames. Also be sure not to smoke during the work.
(3) Keep rubber and leather parts away from gasoline.
2. Fuel spill prevention procedure
CAUTION:
·Perform this procedure when the engine coolant temperature is 60°C {140°F} or less.
·Always perform the fuel spill prevention procedure before removing the fuel system parts.
·Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line.
·Always perform the fuel spill prevention procedure before removing the fuel system parts.
·Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line.
(1) Remove the relay block cover UPR.
(2) Remove the fuel pump fuse from the engine compartment relay block.
Captions in illustration
| *1 |
Engine compartment relay block |
(3) Start the engine.
(4) Turn the ignition to OFF after the engine stalls by itself.
(5) Crank the engine again and check that it does not start.
NOTE:
Since a diagnostic code may be detected, check/clear the diagnostic code after the work is completed. (Refer to )
)(6) Remove the fuel tank cap to release the pressure in the fuel tank.
(7) Disconnect the battery ground terminal. (Refer to )
)(8) Install the fuel pump fuse.
(9) Install the relay block cover UPR.
3. Fuel system (quick type A)
(1) When disconnecting the fuel tube connector (quick type A), adhere to the following precautions.
(a) Release the two claws in the retainer of fuel tube connector and push down the retainer as shown in the figure to disconnect the fuel tube connector from the pipe.
Captions in illustration
| *1 |
Retainer |
 |
Push |
 |
Lower |
 |
Pull |
(b) If the fuel tube connector is seized on the pipe, hold the pipe and push/pull the fuel tube connector to release it, and then disconnect the fuel tube connector.
CAUTION:
·Before starting the work, remove the foreign matters such as dirt on the fuel tube connector.
·Since the fuel tube connector seals the fuel tube connector and pipe with the O-ring, pay special attention to the damage and foreign matters on the connection.
·Never use any tools.
·After the fuel tube is disconnected, protect the connection with a vinyl bag.
·If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it, and then pull out it.
·Since the fuel tube connector seals the fuel tube connector and pipe with the O-ring, pay special attention to the damage and foreign matters on the connection.
·Never use any tools.
·After the fuel tube is disconnected, protect the connection with a vinyl bag.
·If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it, and then pull out it.
Captions in illustration
| *1 |
Pipe |
| *2 |
Retainer |
| *3 |
Nylon tube |
| *4 |
Fuel tube connector |
| *5 |
O-ring |
| *6 |
Top hat |
4. Fuel system (quick type B)
(1) When disconnecting the fuel tube connector (quick type B) using the SST, adhere to the following precautions.
(a) Before disconnecting the fuel tube connector, check the fuel tube connector and pipe for dirt or dust. If dirt or dust is found, clean them.
(b) Attach the SST to the pipe. Push in the SST to disconnect the fuel tube connector from the pipe.
SST
42099AE000
Captions in illustration
| *1 |
Holding portion |
| *2 |
SST |
|
|
Push |
|
|
Pull |
CAUTION:
·Hold the holding portion of the connector to pull out it in axial direction.
·If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the SST pushed in, and then pull out fuel tube connector.
·When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
·Catch the fuel from the tube using a container to prevent it from splashing.
·If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the SST pushed in, and then pull out fuel tube connector.
·When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
·Catch the fuel from the tube using a container to prevent it from splashing.
(c) After disconnecting the fuel tube, check the seal surface of pipe for dirt or dust.
(d) Make sure that the top hat or O-ring does not fall off.
(2) When disconnecting the fuel tube connector (quick type B) without the SST, adhere to the following precautions.
(a) Before disconnecting the fuel tube connector, check the fuel tube connector and pipe for dirt or dust. If dirt or dust is found, clean them.
(b) Push the retainer in the direction of the arrow, disconnect the fuel tube connector from pipe.
Captions in illustration
| *1 |
Retainer |
| *2 |
Holding portion |
|
|
Push |
|
|
Pull |
CAUTION:
·Hold the holding portion of the connector to pull out it in axial direction.
·If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the retainer pushed in, and then pull out fuel tube connector.
·When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
·Catch the fuel from the tube using a container to prevent it from splashing.
·If the fuel tube connector is seized on the pipe, push and pull the fuel tube connector to release it with the retainer pushed in, and then pull out fuel tube connector.
·When disconnecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
·Catch the fuel from the tube using a container to prevent it from splashing.
(c) After disconnecting the fuel tube, check the seal surface of pipe for dirt or dust.
(d) Make sure that the top hat or O-ring does not fall off.
(3) When connecting the fuel tube connector (quick type B), adhere to the following precautions.
(a) Make sure there are no damage or dust on connections. If necessary, clean the seal surface of pipe.
(b) When reusing the retainer, make sure that neither damage nor deformation exist on the retainer. If it is faulty, replace it with a new retainer.
Captions in illustration
| *1 |
When disconnected with the SST |
| *2 |
When disconnected without the SST |
| *3 |
Seal surface |
| *4 |
Retainer |
(c) Align the axis of fuel tube connector and the axis of pipe, push in the fuel tube connector until a clicking sound is heard from the retainer.
Captions in illustration
| *1 |
When disconnected with the SST |
| *2 |
When disconnected without the SST |
| *3 |
Holding portion |
| *4 |
Retainer |
CAUTION:
·Hold the holding portion of the connector to push in it in axial direction.
·When connecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
·When connecting the connector, do not bend or twist the fuel tube forcibly. If the tube is bent, replace with a new part.
(d) After the fuel tube connector is connected, make sure that the fuel tube connector and pipe are connected securely.
Captions in illustration
| *1 |
Fuel tube connector |
| *2 |
Retainer |
| *3 |
Pipe |
CAUTION:
·Make sure that the two retainer pawls are engaged in their mating positions in the quick connector.
·Make sure that there are no fuel leakages from the fuel tube and its connection.
·Make sure that there are no fuel leakages from the fuel tube and its connection.
FUNCTION INSPECTION
1. Fuel pressure check (low-pressure side)
(1) Fuel pressure gauge installation (port injection side)
(a) Perform the fuel spill prevention procedure. (Refer to )
)CAUTION:
Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line.
(b) Loosen the hose clamp, and disconnect the fuel hose.
(c) Install the fuel pressure gauge to the vehicle.
(d) Wipe off any spilt fuel.
(2) Fuel pressure gauge installation (cylinder injection side)
(a) Perform the fuel spill prevention procedure. (Refer to )
)CAUTION:
Since a small amount of residue pressure exists in the fuel line after the fuel spill prevention procedure, prevent the fuel from splashing when disconnecting the fuel line.
(b) Loosen the hose clamp, and disconnect the fuel hose.
(c) Install the fuel pressure gauge to the vehicle.
(d) Wipe off any spilt gasoline.
(3) Fuel pressure check
(a) Measure the fuel pressure while engine idling after warming up the engine.
Standard value
: 350 to 500 kPa {4.0 to 5.0 kgf/cm2} {51 to 72 psi}
(4) Perform the fuel spill prevention procedure. (Refer to )
)(5) Fuel pressure gauge removal
(a) Be careful not to splash gasoline and remove the fuel pressure gauge.
(b) Using the hose clamp, connect the fuel hose.
Standard value:
Standard value:
Tightening torque=1.3N·m
{
13kgf·cm}
{1.0ft·lbf}
2. Fuel pressure check (high pressure side)
(1) Connect the SSM3 to the DLC.
(2) Turn the ignition switch to ON.
(3) Start the engine and check the value in [Data monitor] → [Fuel Rail Pressure] at idling.
Standard value
: 3.5 to 4.5 MPa {35.7 to 45.9 kgf/cm2} {507.5 to 652.5 psi}
3. D-4S inspection (power balance) active test
(1) Connect the SSM3 to the DLC.
(2) Start the engine, select [Active Test] → [D-4S (power balance)] according to the screen display and select [Port injection] or [Cylinder injection].
(3) ‘Check the idle state after the injection to the executed cylinder of [#1 to #4] is stopped.
Criteria
: The idle speed shall vary.
CAUTION:
Only one cylinder can be tested at a time and multiple cylinders shall not be tested.
4. Fuel leakage check
(1) Make sure that there are no fuel leakages from the fuel system with the fuel pressure.
PARTS LOCATION
CIRCUIT FIGURE
Captions in illustration
| *A |
Direct injection side |
- |
- |
| *1 |
Throttle body ASSY |
*2 |
Fuel injector ASSY |
| *3 |
Fuel pressure pulsation damper ASSY |
*4 |
Cylinder |
| *5 |
Fuel pressure sensor |
*6 |
Spill valve solenoid |
| *7 |
Fuel pump ASSY (High pressure side) |
*8 |
Camshaft |
| *9 |
Fuel tank ASSY |
*10 |
Jet pump |
| *11 |
Fuel pressure regulator |
*12 |
Fuel pump ASSY |
| *13 |
Fuel sender gauge ASSY (Fuel sender gauge main) |
*14 |
Fuel pump |
| *15 |
Fuel filter |
*16 |
Fuel sub sender gauge ASSY |
| *17 |
Fuel sender gauge ASSY NO.2 (Fuel sender gauge sub) |
- |
- |
| *a |
To fuel injector (Port injection side) |
*b |
High pressure side fuel line |
| *c |
Low pressure side fuel line |
- |
- |
Captions in illustration
| *A |
Port injection side |
- |
- |
| *1 |
Throttle body ASSY |
*2 |
Fuel injector ASSY |
| *3 |
Fuel pressure pulsation damper ASSY |
*4 |
Fuel delivery pipe |
| *5 |
Fuel tank ASSY |
*6 |
Jet pump |
| *7 |
Fuel sub sender gauge ASSY |
*8 |
Fuel sender gauge ASSY NO.2 (Fuel sender gauge sub) |
| *9 |
Fuel pump ASSY |
*10 |
Fuel pressure regulator |
| *11 |
Fuel sender gauge ASSY (Fuel sender gauge main) |
*12 |
Fuel pump |
| *13 |
Fuel filter |
- |
- |
| *a |
To fuel pump ASSY (High pressure side) |
*b |
Low pressure side fuel line |
Captions in illustration
| *1 |
Throttle body ASSY |
*2 |
Fuel pressure sensor |
| *3 |
Fuel pump ASSY (High pressure side) |
*4 |
Spill valve solenoid |
| *5 |
Engine control computer |
*6 |
Injector driver |
| *7 |
Fuel pump control computer |
*8 |
Fuel tank ASSY |
| *9 |
Fuel pump ASSY |
*10 |
Battery |
| *11 |
Camshaft |
*12 |
Fuel injector ASSY (Cylinder injection side) |
| *13 |
Fuel injector ASSY (Port injection side) |
- |
- |
1. Fuel injector ASSY (Cylinder injection side)
2. Fuel injector ASSY (Port injection side)
