Fuel Line Inspection

Flammable - Keep Fire Away

NOTE:
How to read the torque specifications.
Refer to the Fuel and Emissions Systems Service Precautions before disconnecting the fuel line.
Fuel may cause flammable gas leaks and may result in fire. Keep sparks, flame and, cigarettes away.

1. Fuel Line - Inspect

NOTE:
Check the fuel system lines and hoses for damage, leaks, and deterioration. Replace any damaged parts.
Check all clamps, and make sure they are properly positioned and tightened.
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Make sure the clamps are in the position of the ranges shown.
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Align the marks on the hoses and the pipes.
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There should be no clearance between the hoses and the pipes.

KA/KC models

KX models

KX models


Fuel Leak Check

2. High Pressure Fuel Pump Cover - Remove


NOTE:
Do not disconnect the water bypass hoses.
Do not bend the water bypass hoses excessively.

6. Fuel Leak - Check
1.
Apply commercially available Met-L-Check D-70 Developer to the joint of the injectors (A), the fuel rail (B), and the high pressure fuel pump (C). Set the probe of the leak detector (Snap-on Combustible Gas Leak Detector) on the joint.
2.
Install the intake manifold and the throttle body with the gaskets that had used on them.
NOTE: The intake manifold gasket and the throttle body gasket will be replaced after the fuel leak check.
3.
Turn the vehicle to the ON mode, but do not operate the starter. After the fuel pump runs for about 2 seconds, the low pressure fuel line will be pressurized. Repeat this two or three times, then check for fuel leakage.
4.
Start the engine. Hold the engine speed at 3,000 rpm for 1 minute, and stop the engine.
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If the fuel line is leaking, stop the engine immediately, and turn the vehicle to the OFF (LOCK) mode.
5.
NOTE:
Do not disconnect the water bypass hoses.
Do not bend the water bypass hoses excessively.
6.
Check for fuel leakage to joint of the injectors, the fuel rail, and the high pressure fuel pump.
NOTE:
If there are no leaks, this procedure is complete.
If you find a leak, repair it.

10. High Pressure Fuel Pump Cover - Install

Non-return Valve Inspection

1. Non-return Valve - Remove

Non-return Valve A

Non-return Valve B
NOTE:
When removing non-return valve A, remove the purge pipe.
When removing non-return valve B, remove the engine cover.

2. Non-return Valve - Inspection
1.
Connect the vacuum pump to the non-return valve as shown. Note the direction of the arrow on the valve
2.
Apply vacuum to the valve.
If it holds vacuum, go to next step.
If it doesn’t hold the vacuum, replace the non-return valve.
3.
Connect the vacuum pump to the non-return valve as shown. Note the direction of the arrow on the valve.
4.
Apply vacuum to the valve.
If it holds vacuum, replace the non-return valve.
If it doesn’t hold the vacuum, the non-return valve is OK.