Precautions on Fuel System Service

PRECAUTION ON FUEL SYSTEM SERVICE

- Work must be done with no smoking, in a well-ventilated area and away from any open flames.
- As fuel feed line (between fuel pump and fuel pressure regulator) is still under high fuel pressure even after engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or disconnected.
Before loosening or disconnecting fuel feed line, make sure to release fuel pressure according to "FUEL PRESSURE RELIEF PROCEDURE". A small amount of fuel may be released after the fuel line is disconnected. In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop cloth. Put that cloth in an approved container when disconnection is completed.
- Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.

















- Fuel or fuel vapor hose connection varies with each type of pipe. When reconnecting fuel or fuel vapor hose, be sure to connect and clamp each hose correctly referring to left figure Hose Connection. After connecting, make sure that it has no twist or kink.
- When installing fuel filter union bolt or plug bolt on union bolt, always use new gasket and tighten it to specified torque.
- When installing injector, fuel feed pipe or fuel pressure regulator, lubricate its 0 ring with spindle oil or gasoline.
- When connecting fuel pipe flare nut, first tighten flare nut by hand and then tighten it to specified torque.

FUEL PRESSURE RELIEF PROCEDURE

CAUTION: This work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst.

After making sure that engine is cold, release fuel pressure as follows.
1) Place transmission gear shift lever in "Neutral" (Shift selector lever to "P" range for AT model), set parking brake, and block drive wheels.
2) Remove relay box cover.





3) Disconnect fuel pump relay from relay box.
4) Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat cranking engine 2-3 times for about 3 seconds each time to dissipate fuel pressure in lines. Fuel connections are now safe for servicing.
6) Upon completion of servicing, connect fuel pump relay to relay box and install relay box cover.

FUEL LEAKAGE CHECK PROCEDURE
After performing any service on fuel system, check to make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pressure to fuel line (till fuel pressure is felt by hand placed on fuel return hose.)
2) In this state, check to see that there are no fuel leakages from any part of fuel system.