Engine stall, hard to start, rough idling

• Deteriorated fuel

• Bent or kinked fuel hose/fuel tank breather hose

• Faulty IACV

• Intake air leak

• Faulty ignition system

• Faulty MAP sensor

• Faulty charging system

 

Backfiring or misfiring during acceleration

• Faulty ignition system

 

Engine lacks power

• Bent or kinked fuel hose/fuel tank breather hose

• Clogged fuel filter

• Faulty fuel pump or its drive circuit

• Faulty injector

• Faulty ignition system

• Clogged air cleaner element

 

 

7-2

FUEL SYSTEM

COMPONENT LOCATION

 

 

7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

 

	7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)
	10 N·m (1.0 kgf·m, 7 lbf·ft)
27 N·m (2.8 kgf·m,
20 lbf·ft)
	7.0 N·m (0.7 kgf·m,
		3.0 N·m (0.3 kgf·m,
			5.2 lbf·ft)
				2.2 lbf·ft)

 

3.0 N·m (0.3 kgf·m, 2.2 lbf·ft)

 

27 N·m (2.8 kgf·m, 20 lbf·ft)

 

7-3

FUEL SYSTEM

FUEL LINE INSPECTION

 

FUEL PRESSURE RELIEVING

Before disconnecting fuel feed hose, relieve pressure from the system as follows.

 

1. Turn the ignition switch OFF.

 

2. Disconnect the fuel pump 3P (Black) connector [1].

 

3. Start the engine, and let it idle until the engine stalls.

 

4. Turn the ignition switch OFF.

 

5. Disconnect the battery negative (–) cable (page 19-

4).

 

[1]

 

QUICK CONNECT FITTING REMOVAL

Do not bend or twist fuel feed hose.

 

1.	Relieve the fuel pressure (page 7-4).
2.	Remove the three bolts [1] and lift up the fuel tank
[1]
	[2] from the frame.

 

 

		[2]		[1]
3. Check the fuel quick connect fitting [1] for dirt, and
clean if necessary.
			[1]
Place a shop towel [2] over the quick connect fitting.

 

[2]

 

 

7-4

FUEL SYSTEM

4.	Pull and release the joint rubber [1] from the
	retainer.
				[2]
5.	Hold the connector with one hand and squeeze the
	retainer tabs [2] with the other hand to release the
	locking pawls [3].
	Pull the connector off and remove the retainer.
•	Absorb the remaining fuel in the fuel feed hose from
	flowing out with a shop towel.
•	Be careful not to damage the hose or other parts.
•	Do not use tools.
•	If the connector does not move, keep the retainer
	tabs pressed down, and alternately pull and push		[1]				[3]
	the connector until it comes off easily.
6.	To prevent damage and keep foreign matter out,
	cover the disconnected connector and pipe end with
	the plastic bags [1].
					[1]

 

QUICK CONNECT FITTING

INSTALLATION

 

• Always replace the retainer and joint rubber of the quick connect fitting when the fuel feed hose is disconnected.

 

• Replace the retainer and joint rubber with the same manufacturer’s item that was removed.

 

• Do not bent or twist fuel feed hose.

 

1. Insert a new retainer [1] into the connector [2].

• Align new retainer locking pawls with the connector grooves.

 

 

[1]

 

 

[2]

 

 

Align

 

7-5

FUEL SYSTEM

 

2. Set a new joint rubber [1] to the joint [2] as shown.

 

Press the quick connect fitting [3] onto the pipe until both retainer pawls lock with a "CLICK".

• Align the quick connect fitting with the joint.

• If it is hard to connect, put a small amount of engine oil on the joint end.

 

3. Make sure the connection is secure and that the pawls [1] are firmly locked into place; check visually and by pulling the connector.

 

4. Make sure the joint rubber [2] is positioned between the retainer [3] and joint flange [4] as shown.

 

5. Reposition the fuel tank [1] and tighten the three bolts [2].

 

FUEL PRESSURE NORMALIZATION

 

1. Connect the fuel pump 3P (Black) connector [1]. Connect the battery negative (–) cable (page 19-4).

2. Turn the ignition switch ON and engine stop switch " ".

• Do not start the engine.

 

The fuel pump will run for about 2 seconds, and fuel pressure will rise.

 

Repeat 2 or 3 times, and check that there is no leakage in the fuel supply system.

 

Turn the ignition switch OFF.

[1]

[3]

 

 

[1]

 

 

[2]

 

 

[2]

 

[1]

 

 

[4] ^[3]

[2]

 

[1]

[2]

 

[1]

 

7-6

FUEL SYSTEM

 

FUEL PRESSURE TEST

 

Relieve the fuel pressure and disconnect the quick
[3]
connect fitting (page 7-4).
Attach the special tools as follows:
TOOLS:
[1] Fuel pressure gauge	07406-0040004
[2] Pressure gauge manifold	07ZAJ-S5A0111
[3] Hose attachment, 9 mm/9 mm	07ZAJ-S5A0120
[4] Hose attachment, 8 mm/9 mm	07ZAJ-S7C0100
[5] Attachment joint, 8 mm/9 mm	07ZAJ-S7C0200

 

Temporarily connect the battery negative (–) cable and
[5]
fuel pump 3P (Black) connector.
Start the engine and let it idle.
Read the fuel pressure.

 

STANDARD: 343 kPa (3.5 kgf/cm², 50 psi)

 

If the fuel pressure is higher than specified, replace the fuel pump assembly.

 

If the fuel pressure is lower than specified, inspect the following:

 

– Fuel line leaking

– Pinched or clogged fuel feed hose or fuel tank breather hose

– Fuel pump unit (page 7-8)

– Clogged fuel filter

 

After inspection, relieve the fuel pressure (page 7-4).

 

Remove the fuel pressure gauge, attachment and manifold from the fuel pump.

 

Connect the quick connect fitting (page 7-5).

 

[1]

 

 

[2]

 

[4]

 

 

Wipe off spilled out gasoline.

 

FUEL FLOW INSPECTION

 

Relieve the fuel pressure and disconnect the quick connect fitting (page 7-4).

Connect the special tool to the fuel pump joint.

 

TOOL:

 

[1] Hose attachment, 8 mm/9 mm 07ZAJ-S7C0100

 

Place the end of the hose into an approved gasoline container.

 

Temporarily connect the battery negative (–) cable and fuel pump 3P (Black) connector.

 

Turn the ignition switch ON and engine stop switch " ". Measure the amount of fuel flow.

• The fuel pump operates for 2 seconds. Repeat 5 times to meet the total measuring time.

 

• Return fuel to the fuel tank when the first fuel is flowed.

 

Amount of fuel flow:

 

83 cm³ (2.81 US oz, 2.92 Imp oz) minimum/ 10 seconds at 12 V

 

If fuel flow is less than specified, inspect the following:

 

– Fuel pump unit (page 7-8)

– Clogged fuel filter

 

Connect the quick connect fitting (page 7-5).

 

 

[1]

 

 

7-7

FUEL SYSTEM

 

FUEL TANK

 

REMOVAL/INSTALLATION

 

Relieve the fuel pressure and disconnect the quick connect fitting (page 7-4).

 

Lift up the fuel tank [1] and release the fuel feed hose [2] from the hose clamps [3].

 

Disconnect the fuel tank breather hose [4] and remove the fuel tank.

 

Install the fuel tank in the reverse order of removal. Connect the quick connect fitting (page 7-5).

 

 

FUEL PUMP UNIT

 

SYSTEM INSPECTION

 

Turn the ignition switch ON and engine stop switch " " and confirm that the fuel pump operates for 2 seconds.

 

If the fuel pump does not operate, inspect as follows: Turn the ignition switch OFF.

 

Disconnect the fuel pump 3P (Black) connector [1]. Turn the ignition switch ON and engine stop switch " ".

 

Measure the voltage at the fuel pump 3P (Black) connector terminals of the wire side.

 

CONNECTION: Brown/red (+) – Green (–) STANDARD: Battery voltage

 

There should be standard voltage for a few seconds. If there is standard voltage, replace the fuel pump unit. If there is no standard voltage, inspect the following:

– Main fuse (30 A)

– FI, IGN fuse (10 A)

– Ignition switch (page 20-11)

– Engine stop switch (page 20-11)

– Fuel pump relay (page 7-10)

– Open circuit in Brown/red or Green wire

 

 

[1]

 

[4]

 

[3]

 

[1]

 

 

[3]

 

[2]

 

 

7-8

FUEL SYSTEM

 

REMOVAL/INSTALLATION

Do not disassemble the fuel pump.

 

Remove the fuel tank (page 7-8). Clean around the fuel pump.

 

Loosen the fuel pump mounting nuts [1] in a crisscross pattern in 2 or 3 steps and remove the nuts.

 

Remove the fuel pump unit [2] from the fuel tank, being careful not to damage the fuel level sensor float arm.

 

 

Remove the packing [1] from the fuel pump unit [2].

 

Install a new packing onto the fuel pump unit.

 

• Always replace the packing with a new one.

• Be careful not to pinch the dirt and debris between the fuel pump unit and packing.

 

Install the fuel pump [1] into the fuel tank.

 

Install and tighten the fuel pump mounting nuts [2] to the specified torque in the sequence as shown.

 

TORQUE:12 N·m (1.2 kgf·m, 9 lbf·ft)

 

Install the fuel tank (page 7-8).

 

[2]

 

[2]

 

[1]

[1]

 

5 1

 

4

 

3

 

6

 

[1]

 

 

[2]

 

INSPECTION

 

Check the fuel pump unit [1] for wear or damage,
[1]
replace it if necessary.

 

7-9

FUEL SYSTEM

FUEL PUMP RELAY

 

INSPECTION

 

Remove the left side cover (page 2-3).

[2]

Remove the dust cover [1]

 

Remove the fuel pump relay [2].

 

 

[1]

 

Connect a ohmmeter to the fuel pump relay [1]
[1]
terminals.

Connect a 12 V battery to the fuel pump relay terminals as shown.

 

There should be continuity only when 12 V battery is connected.

 

If there is no continuity when the 12 V battery is connected, replace the fuel pump relay.

 

 

AIR CLEANER HOUSING

 

REMOVAL/INSTALLATION

 

Remove the sub-frame (page 2-12). Remove the bolts [1] and air cleaner housing. Installation is in the reverse order of removal.

 

TORQUE:

 

Air cleaner housing mounting bolt: 7.0 N·m (0.7 kgf·m, 5.2 lbf·ft)

 

[2]

 

[1]

 

 

7-10

FUEL SYSTEM

 

THROTTLE BODY

 

REMOVAL

 

Remove the fuel tank (page 7-8). Disconnect the sensor unit 5P connector [1].

 

Disconnect the IACV 4P (Black) connector [1] and injector 2P (Gray) connector [2].

 

Release the wire band [3] from the clamp stay.

 

 

Loosen the throttle cable A adjuster lock nut [1] and adjuster [2] then disconnect the throttle cable A [3] from the throttle drum and cable stay.

 

Loosen the throttle cable B nut [4] then disconnect the throttle cable B [5] from the throttle drum and cable stay.

 

 

Loosen the connecting hose band screw [1] and insulator band screws [2], then remove the throttle body assembly [3].

 

[1]

[2]

[1]

 

[3]

		[1]		[2]
[3]

 

			[4]
		[5]
[3]			[1]

 

[2]

 

 

7-11

FUEL SYSTEM

DISASSEMBLY/ASSEMBLY

 

• Do not remove the sensor unit unless it is replaced.

• The throttle body/sensor unit is factory pre-set. Do

	not disassemble in a way other than shown in this
	manual.
•	Do not snap the throttle valve from full open to full
	close after the throttle cable has been removed. It
	may cause incorrect idle operation.
•	Do not damage the throttle body. It may cause
	incorrect throttle valve operation.
•	Do not loosen or tighten the white painted nut and
	screw [1] of the throttle body. Loosening or
	tightening it can cause throttle valve and idle control
	failure.
•	Always clean around the throttle body before each
	sensor removal to prevent dirt and debris from	[1]
	entering the air passage.

 

Remove the following

– Sensor unit (page 4-44)

– Injector (page 7-14)

– IACV (page 7-15)

 

Clean the air passage of the throttle body using compressed air.

 

• Cleaning the air passages and sensor hole with a piece of wire will damage the throttle body.

 

Check the air passage for clogs.

 

 

Disassemble and assemble the throttle body as following illustration.

 

_{THROTTLE CABLE STAY} ^{3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)} INJECTOR

CUSHION RING

3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)

SEAL

RING

O-RING

CLAMP STAY

THROTTLE BODY INSULATOR

5.1 N·m (0.5 kgf·m,

3.8 lbf·ft)

INJECTOR JOINT

SENSOR UNIT

2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)

SETTING PLATE

IACV

THROTTLE BODY

O-RING

O-RING

3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)

 

7-12

FUEL SYSTEM

 

Install the throttle body insulator [1] to the throttle body by aligning the tab of the throttle body with the groove of the throttle body insulator.

• Install the throttle body insulator with "KZZ" mark [2] facing the cylinder head.

 

• Align the insulator band hole with the insulator boss.

 

INSTALLATION

 

Install the throttle body assembly [1] to the cylinder head by aligning the tab of the cylinder head with the groove of the throttle body insulator.

 

Tighten the insulator band screws [2] to the specified torque.

 

TORQUE:4.2 N·m (0.4 kgf·m, 3.1 lbf·ft)

 

After tightening the insulator band screws, check that the band ends are seated with each other.

 

Tighten the air cleaner connecting hose band screw [3] to the specified torque.

 

TORQUE:1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)

 

Connect the throttle cables [1] to the throttle drum and throttle cable stay.

 

Tighten the throttle cable B nut [2] to the specified torque.

 

TORQUE:3.0 N·m (0.3 kgf·m, 2.2 lbf·ft)

 

 

Align	[2]
Align	[1]
[1]	[3]

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