PRECAUTION
HINT
Any diagnostic trouble code (DTC) retained in the ECM will be erased when the negative (-) terminal cable is removed from the battery. If necessary, read the DTC before removing the negative (-) terminal cable from the battery.
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- BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
- DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM
- KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS
- MAINTENANCE PRECAUTIONS To prevent engine misfire, these precautions should be taken. Check the battery terminals for proper connection. After repair, check that the ignition coil terminals and all other ignition system lines are reconnected securely. When cleaning the engine compartment, be especially careful to protect the electrical system from water. Observe the following when handling the heated oxygen sensors. Do not drop the sensor or hit it against an object. The sensor should be free from any contact with water.
- IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the «PRECAUTION»(ref-180907-S08801071082005073000000).
- AIR INDUCTION SYSTEM Removal of the engine oil dipstick, oil filler cap, PCV hose may break the engine. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head may allow air suction and break the engine.
- ELECTRONIC CONTROL SYSTEM Before removing the SFI wiring connectors, terminals, first disconnect the power by turning the ignition switch OFF or disconnecting the negative (-) terminal cable from the battery. HINT: Be sure to check the DTC before disconnecting the negative (-) terminal cable from the battery. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (-) cables. Do not give a severe impact to the SFI parts during removal or installation. Handle all the SFI parts carefully, especially the ECM. Be careful during troubleshooting. Numerous transistor circuits are used and even slight terminal contact can cause further troubles. Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting into the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care should be taken when pulling out and inserting the wiring connectors. Release the lock and pull out the connector, pulling on the connectors. Fully insert the connector and check that it is locked. Use SST for the inspection or test of the injector or its wiring connector. SST 09842-30080
- FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe these procedures: Disconnect the fuel pump connector. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. Put a container under the connection. Slowly loosen the connection. Disconnect the high fuel pressure line. Reconnect the fuel pump connector. Observe the following when removing and installing the injector: Never reuse the O-ring. When placing a new O-ring on the injector, take care not to damage it in anyway. Coat a new O-ring with spindle oil or gasoline before installing. Never use engine oil, gear oil and brake oil. Install the injector to the delivery pipe and cylinder head (Scheme 120) Observe the following when disconnecting the fuel tube connector (quick type): Check if there is any dirt like mud in the pipe and around the connector before disconnecting the fuel tube connector. If necessary, clean the dirt away. Disconnect the fuel pipe clamp from the connector. Be sure to disconnect them with hands. When the connector and the pipe are stuck, push and pull the connector. Then disconnect and pull it out. Do not use any tools at this time. Check if there is any dirt on the seal surface of the disconnected pipe. If necessary, clean the dirt away. Prevent the disconnected pipe and connector from being damaged and foreign objects mixing in by covering them with a vinyl bag. Observe the following when connecting the fuel tube connector (quick type): Check if there is any damage or foreign objects in the connected part of the pipe. Match the axis of the connector with the axis of the pipe, and push into the connector until a "click" sound is heard. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe. After having finished the connection, pull the pipe and the connector to ensure secure connection. Check to make sure no fuel leak is present. If the result is not specified, repair or replace. Install the fuel pipe clamp to the connector. Check to make sure no fuel leak is present. If the result is not specified, repair or replace. Observe the following when disconnecting the fuel tube connector (metallic type): HINT: The structure of the metallic connector is (Scheme 126) Check if there is any dirt like mud in the pipe and around the connector before disconnecting the fuel tube connector. If necessary, clean the dirt away. Assemble SST to the connection (Scheme 127) SST 09268-21010 Turn the SST, align the retainers inside the connector with the SST chamfered parts and insert the SST into the connector. While holding the SST, pull the connector towards the SST to put the retainers on the SST chamfered parts. Slide the SST and connector together towards the fuel tube assembly. Observe the following when connecting the fuel tube connector (metallic type): Check if there is any damage or foreign objects in the connected part of the pipe. Match the axis of the connector with the axis of the pipe, and push into the connector until a "click" sound is heard. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe. After having finished the connection, pull the pipe and the connector to ensure secure connection. Check to make sure no fuel leak is present. If the result is not specified, repair or replace. Observer the following when handling the nylon tube: Pay attention not to turn the connected part of the nylon tube and the quick connector with tube when connecting them. Pay attention not to kink the nylon tube. Do not remove the nylon tube. Do not close the piping with the nylon tube by bending it. Check that there is no fuel leak after doing maintenance anywhere on the fuel system. Connect the hand-held tester to the DLC3. Connect the hand-held tester to the DLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. Select the ACTIVE TEST mode on the hand-held tester. NOTE: Do not start the engine. HINT: Please refer to the hand-held tester operator's manual for further details. If you have no hand-held tester, connect the battery's positive (+) and negative (-) leads to the fuel pump connector (see «FUEL PUMP»(ref-239091-S02930303862006072600000) ). Check that there is no leak from any parts of the fuel system. Turn the ignition switch OFF. Disconnect the hand-held tester from the DLC3.
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- CHECK FUEL PUMP OPERATION Connect the hand-held tester to the DLC3. Connect the hand-held tester to the DLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. NOTE: Do not start the engine. Select the ACTIVE TEST mode on the hand-held tester. HINT: Please refer to the hand-held tester operator's manual for further details. If you have no hand-held tester, connect the battery's positive (+) negative (-) leads the fuel pump connector (see step 3 ). Check that there is pressure in the fuel inlet tube from the fuel line. HINT: If there is fuel pressure, you will hear the sound of the fuel flowing. If there is no pressure, check the fusible link, fuses, EFI Main relay, fuel pump, ECM and wiring connector. Turn the ignition switch OFF. Disconnect the hand-held tester from the DLC3.
- CHECK FUEL PRESSURE Check the battery positive voltage is above 12 V. Disconnect the negative (-) terminal cable from the battery. Purchase a new fuel tube and remove the fuel tube connector from its pipe. Fuel tube: Part No. 23901-22110 Disconnect the fuel tube clamp from the fuel tube connector. Disconnect the fuel inlet tube (fuel tube connector) from the fuel pipe. NOTE: Disconnect the fuel tube connector (quick type) after observing the precaution (see «SFI SYSTEM»(ref-239091-S33576169842006072600000) ). If there is retained pressure in the fuel line, prevent it from splashing inside the engine compartment. Install SST (pressure gauge) (Scheme 138)using SST and fuel tube connector. SST 09268-41047, 09268-45014 (09268-41250) Wipe off any splattered gasoline. Reconnect the negative (-) terminal cable to the battery. Connect the hand-held tester to the DLC3 (see step 1 ). Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm 2,44 to 50 psi) If the pressure is high, replace the fuel pressure regulator. If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. Disconnect the hand-held tester from the DLC3. Start the engine. Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm 2,44 to 50 psi) Stop the engine. Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm 2,21 psi) or more If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. After checking the fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST and fuel tube connector to prevent gasoline from splashing. SST 09268-41047, 09268-45014 Reconnect the fuel inlet tube (fuel tube connector). CAUTION: Connect the fuel tube connector (quick type) observing the precaution (See «SFI SYSTEM»(ref-239091-S33576169842006072600000) ). Reconnect the fuel tube clamp to the fuel tube connector. Reconnect the negative (-) terminal cable to the battery. Check for fuel leak (see «SFI SYSTEM»(ref-239091-S33576169842006072600000) ).
- INSPECT FUEL PUMP Remove the LH rear seat. Remove the floor service hole cover. Disconnect the fuel pump & sender gauge connector. Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 to 3.0 ohm at 20°C (68°F) If the resistance is not as specified, replace the fuel pump. Inspect the fuel pump operation. Connect the battery's positive (+) lead to terminal 4 of the connector and the negative (-) lead to terminal 5. Check that the pump operates. NOTE: These tests must be performed within 10 seconds to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. If operation is not as specified, replace the fuel pump. Reconnect the fuel pump & sender gauge connector. Reinstall the floor service hole cover. Reinstall the LH rear seat.
