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(g) Using a 5 mm socket hexagon wrench, remove the
4 bolts. (*1)
(h) Remove the 2 nuts, 2 bolts, and intake air surge
tank. (*2)
(i) Remove the gasket from the intake air surge tank.
15. DISCONNECT FUEL TUBE SUB-ASSEMBLY
(a) Remove the No. 2 fuel pipe clamp.
(b) Pinch the tube connector and pull out the fuel pipe.
NOTICE:
• Check that there is no dirt or other foreign
objects around the connector before
disconnecting it. Clean the connector as
necessary.
• It is necessary to prevent mud or dirt from
entering the quick connector. If mud or dirt
gets in the connector, the O-rings may not
seal properly.
• Only disconnect the quick connector by
hand.
• Do not bend, kink or twist the nylon tubes.
Protect the connector by covering it with a
plastic bag.
• If the pipe and the connector are stuck,
carefully try wiggling or pushing and pulling
on the connector to release it. Pull the
connector off the pipe carefully.
16. REMOVE FUEL INJECTOR ASSEMBLY
(a) Disconnect the 6 fuel injector connectors.
(b) Remove the 5 bolts and fuel delivery pipe sub-
assembly together with the 6 fuel injectors.
NOTICE:
Be careful not to drop the fuel injectors when
removing the fuel delivery pipe sub-assembly.
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FUEL SYSTEM
PRECAUTION
1. PRECAUTION
(a) Before inspecting and repairing the fuel system,
disconnect the cable from the negative (-) battery
terminal.
(b) Do not smoke or work near fire when handling the
fuel system.
(c) Keep gasoline away from rubber or leather parts.
2. DISCHARGE FUEL SYSTEM PRESSURE (*1)
CAUTION:
• Perform the following procedures to prevent fuel
from spilling out before removing any fuel system
parts.
• Pressure will still remain in the fuel line even after
performing the following procedures. When
disconnecting the fuel line, cover it with a shop
rag or a piece of cloth to prevent fuel from
spraying or coming out.
(a) Remove the circuit opening relay from the engine
room relay block.
(b) Start the engine.
(c) After the engine stops, turn the engine switch off.
HINT:
DTC P0171/25 (fuel problem) may be detected.
(d) Crank the engine again. Check that the engine does
not start.
(e) Remove the fuel tank cap to discharge pressure
from the fuel tank.
(f) Disconnect the cable from the negative (-) battery
terminal.
(g) Reinstall the circuit opening relay.
3. FUEL SYSTEM
(a) When disconnecting the high pressure fuel line, a
large amount of gasoline will spill out, so observe
the following procedures:
(1) Discharge the fuel system pressure(*1).
(2) Disconnect the fuel pump tube (See page FU-
30).
(3) Drain the fuel that remains in the fuel pump tube.
(4) To protect the disconnected fuel pump tube from
damage and contamination, cover it with a
plastic bag.
(5) Put a container under the connectors.
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(b) Observe the following precautions when removing
and installing the fuel injectors:
(1) Never reuse an O-ring.
(2) When placing a new O-ring on the injector, do
not damage the O-ring.
(3) Coat a new O-ring with spindle oil or gasoline
before installing it.
NOTICE:
Do not use engine oil, gear oil or brake fluid.
(c) Install the injector to the delivery pipe and the lower
intake manifold as shown in the illustration.
NOTICE:
Before installing the injector, be sure to apply
appropriate lubricant or gasoline to the place
where the delivery pipe or cylinder head
contacts the injector O-rings.
(d) Observe the following precautions when
disconnecting the fuel tube connectors (Quick type
A):
(1) Remove the No. 1 fuel pipe clamp.
(2) Check that there is no dirt or other foreign
objects on the pipe and around the connector
before disconnecting them. Clean them if
necessary.
(3) Disconnect the connector from the pipe by hand.
(4) If the connector and the pipe are stuck, push in
and pull on the connector to release it. Pull the
connector out of the pipe carefully.
(5) Check that there is no dirt or other foreign
objects on the sealing surface of the
disconnected pipe. Clean the surfaces if
necessary.
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(6) Do not damage the disconnected pipe or
connector. Prevent entry of foreign objects by
covering the connectors with plastic bags.
(e) Observe the following precautions when connecting
the fuel tube connectors (Quick Type A):
(1) Check if there is any damage or foreign objects
on the connecting parts of the pipes.
(2) Line up the 2 parts of the pipes to be connected,
and push them together until the connector
makes a "click" sound. If the pipe is difficult to
push into the connector, apply a small amount of
clean engine oil to the tip of the pipe and reinsert
it.
(3) After connecting the pipes, check that the pipe
and connector are securely connected by pulling
on them.
(4) Check for fuel leaks.
(f) Observe the following precautions when
disconnecting the fuel tube connector (Quick type
B):
(1) Before disconnecting the connector, clean off
any dirt that may be present.
(2) Pinch the tabs of the fuel tube retainer to
disengage the 2 claws. Push the retainer down
as shown in the illustration.
HINT:
Be sure to disconnect the connector by hand.
(3) If the connector and pipe are stuck, hold the fuel
pipe by hand, push, and pull on the connector.
Pull the 2 pipes apart to separate the connector.
(4) Check if there is any dirt or any other foreign
objects on the sealing surfaces of the
disconnected pipes. Clean the sealing surfaces
if necessary.
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(5) Do not damage the disconnected pipe or
connector. Prevent entry of foreign objects by
covering the connectors with plastic bags.
(g) Observe the following precautions when connecting
the fuel tube connector (Quick Type B):
(1) Line up the 2 parts of the pipes to be connected,
and fully push the fuel tube connector and pipe
together until they are fully seated. Next, push
the retainer into the connector until its claws
lock. If the pipe is difficult to push in to the
connector, apply a small amount of clean engine
oil to the tip of the pipe and reinsert it.
(2) After connecting the pipes, check that the pipe
and connector are securely connected by pulling
on them.
(3) Check for fuel leaks.
(h) Observe the following precautions when handling a
nylon tube:
CAUTION:
• Do not twist the connector part of the nylon
tube or the quick connector when connecting
them.
• Do not bend or twist the nylon tube.
• Do not remove the EPDM protector on the
outside of the nylon tube.
• Do not pinch or kink the nylon tubes to
prevent fuel leakage.
4. INSPECT FOR FUEL LEAK
(a) Check that there are no fuel leaks from the fuel
system after doing any maintenance or repairs (See
page FU-7).
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ON-VEHICLE INSPECTION
1. INSPECT FOR FUEL PUMP OPERATION AND FUEL
LEAK
(a) Check fuel pump operation.
(1) Connect the intelligent tester to the DLC3.
(2) Turn the engine switch on (IG) and push the
intelligent tester main switch on.
NOTICE:
Do not start the engine.
(3) Select the following menu items: DIAGNOSIS /
ENHANCED OBD II / ACTIVE TEST / FUEL
PUMP / SPD.
(4) Check for pressure in the fuel inlet tube from
the fuel line. Check that sound of fuel flowing in
the fuel tank can be heard. If no sound can be
heard, check the integration relay, fuel pump,
ECM and wiring connector.
(b) Check for fuel leaks (*1).
(1) Check that there are no fuel leaks anywhere on
the system after performing maintenance. If
there is a fuel leak, repair or replace parts as
necessary.
(c) Turn the engine switch off.
(d) Disconnect the intelligent tester from the DLC3.
2. CHECK FUEL PRESSURE
(a) Discharge the fuel system pressure (See page FU-
1).
(b) Using a voltmeter, measure the battery voltage.
Standard voltage:
11 to 14 V
(c) Disconnect the cable from the negative (-) battery
terminal.
(d) Disconnect the fuel hose from the fuel main tube
(See page FU-1).
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FU–82GR-FE FUEL – FUEL SYSTEM
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(e) Install SST (pressure gauge) using SST and a fuel
tube connector as shown in the illustration.
SST 09268-31011 (09268-41500, 90467-13001,
95336-08070), 09268-45014 (09268-41200,
09268-41220, 09268-41250)
(f) Wipe up any gasoline.
(g) Connect the cable to the negative (-) battery
terminal.
(h) Connect the intelligent tester to the DLC3.
(i) Select the following menu items: DIAGNOSIS /
ENHANCED OBD II / ACTIVE TEST / FUEL PUMP
/ SPD.
(j) Measure the fuel pressure.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf*cm
2, 44.1 to 49.7
psi)
• If the fuel pressure is greater than the standard
value, replace the fuel pressure regulator.
• If the fuel pressure is less than the standard
value, check the fuel hoses and connections, fuel
pump, fuel filter and fuel pressure regulator.
(k) Disconnect the intelligent tester from the DLC3.
(l) Start the engine.
(m) Measure the fuel pressure at idle.
Fuel pressure:
304 to 343 kPa (3.1 to 3.5 kgf*cm
2, 44.1 to 49.7
psi)
(n) Stop the engine.
(o) Check that the fuel pressure remains as specified
for 5 minutes after the engine stops.
Fuel pressure:
147 kPa (1.5 kgf*cm
2, 21 psi) or more
If the fuel pressure is not as specified, check the fuel
pump, pressure regulator and/or fuel injectors.
(p) After checking the fuel pressure, disconnect the
cable from the negative (-) battery terminal and
carefully remove the SST to prevent gasoline from
splashing.
(q) Reconnect the fuel tube to the main fuel tube (fuel
tube connector).
(r) Install the No. 1 fuel pipe clamp to the fuel tube
connector.
(s) Check for fuel leaks (*1).
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(c) Remove the 6 injector vibration insulators from the
intake manifold.
(d) Pull out the fuel injectors from the fuel delivery pipe
sub-assembly.
(e) Remove the 6 O-rings from the fuel injectors.
INSPECTION
1. INSPECT FUEL INJECTOR ASSEMBLY
(a) Inspect the injector resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
If the resistance is not as specified, replace the
injector.
(b) Inspect the injection volume.
CAUTION:
This test involves high-pressure fuel and
electricity. Take every precaution regarding the
safe handling of both fuel and electricity.
Perform this test in a safe area, and avoid any
sparks or flames. Do not smoke.
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Tester Connection Condition Specified Condition
1-2 always11.6 to 12.4
at 20C (68F)