FUEL LINE PRESSURE INSPECTION AND FUEL DRAINING PROCEDURE [SKYACTIV-G]

1. FUEL LINE PRESSURE INSPECTION.

Special Service Tool (SST)

49 N013 1A0D Fuel pressure gauge set

Warning

  • Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. To prevent this, complete the following inspection with the engine stopped.
  • Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.
    ― Fuel may cause irritation if it comes in contact with skin and eyes.
    ― If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
  • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.
    Caution
  • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free of foreign material.
  1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  2. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)
  3. Disconnect the quick release connector as shown in the figure. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

4.  Turn the lever of the SST parallel to the hose as shown in the figure.

  1. Insert the SST quick release connector into the fuel pipe until a click is heard.
  2. Insert the quick release connector into the SST until a click is heard.
  3. Verify that the quick release connector is firmly connected by pulling it by hand.
  4. Start the fuel pump using the following procedure.
    (1) Remove the fuel pump relay.

Caution

  • Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.
    (2) Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.

(3) Connect the negative battery terminal and operate the fuel pump. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

  1. Operate the fuel pump for 10 s.
  2. Measure the fuel line pressure.
  • If not within the specification, inspect the following:
    If it less than the specification:
    ― Fuel pump unit
    ― Fuel line for restriction or leakage
    If it exceeds the specification:
    ― Fuel line restriction
    Fuel pressure
    475—555 kPa {4.85—5.65 kgf/cm2, 68.9—80.4 psi}
  1. Disconnect the negative battery terminal to stop the fuel pump. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)
  2. Measure the fuel hold pressure after 5 min.
  3. If not within the specification, inspect the following:
    ― Fuel line leakage
    Fuel hold pressure
    300 kPa {3.06 kgf/cm2, 43.5 psi}
  4. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  5. Disconnect the SST.
  6. Connect the quick release connector. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  7. Complete the “AFTER SERVICE PRECAUTION”. (See AFTER SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

2. FUEL DRAINING PROCEDURE.

Special service tool (SST)

49 N013 101A Body

Warning

  • Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.
    ― Fuel may cause irritation if it comes in contact with skin and eyes.
    ― If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
  • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before performing work on the fuel system, discharge static electricity by touching the vehicle body.
  • Connect a ground wire to the oil-resistant fuel hose for draining fuel and the vehicle because the oil-resistant fuel hose for draining fuel may become electrically charged.

Fuel Siphoning Procedure Using Fuel Pump
Caution

  • Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free of foreign material.
  1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  2. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)
  3. Disconnect the quick release connector as shown in the figure. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

4.  Connect the oil-resistant fuel hose connected to the SST to the disconnected quick release connector and collect the fuel into the gasoline container.

  1. Connect the wiring harness between the oil-resistant fuel hose and the vehicle body using the following procedure.
    (1) Strip off 10 cm {3.9 in} or more of the insulation from both ends of the wiring harness.
    (2) Wrap the wiring harness on one side around the oil-resistant fuel hose.
    (3) Connect the wiring harness on the other side to body ground securely.
  2. Drain the fuel from the fuel tank using the following procedure:
    Caution
  • The fuel pump could be damaged if it is operated while there is no fuel in the fuel tank. Verify the amount of fuel being discharged from the hose and stop operation of the fuel pump when essentially no fuel is being discharged.
    (1) Remove the fuel pump relay.

Caution

  • Short the specified terminals because shorting the wrong terminal of the relay and fuse block may cause malfunctions.
    (2) Using a jumper wire, short fuel pump relay terminals C and D in the relay and fuse block.

(3) Connect the negative battery terminal and operate the fuel pump. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)
― If the fuel pump cannot be operated, remove the fuel using the procedure in the reference. (See Fuel Siphoning Procedure Not Using Fuel Pump.)

  1. Remove the jumper wire to stop the fuel pump.
  2. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

Fuel Siphoning Procedure Not Using Fuel Pump

  1. Complete the “BEFORE SERVICE PRECAUTION”. (See BEFORE SERVICE PRECAUTION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)
  2. Verify the fuel level in the fuel gauge and siphon the fuel.

Fuel siphoning procedure in fuel-filler pipe
Note

  • When removing the hose from the fuel-filler opening, use a rag to prevent fuel spatter.
  • Cut the tip of the hose diagonally so that it can be inserted into the fuel-filler pipe smoothly.
  • When inserting the hose into the fuel-filler pipe, the hose may get stuck. In such cases, rotate the hose so that the hose can be inserted easily.
  1. Siphon the fuel in the fuel-filler pipe.
    (1) Cut the tip of the hose diagonally and place a mark at the position of the specified hose insertion length.
FUEL SYSTEM [SKYACTIV G]