CHAPTER 5:

Fuel System
General information
2004 > 1.8L DOHC >

CIRCUIT DIAGRAM (T8 DOHC)

CIRCUIT DIAGRAM (A6 DOHC)

 2004 > 1.8L DOHC >

SPECIAL TOOLS
Tool (Number and name) Illustration Application
0K2A1 131 AA1 Used for measuring fuel pressure
Fuel pressure gauge
 2004 > 1.8L DOHC >

TROUBLESHOOTING
a. Power supply
a. Battery
b. Fusible link
c. Fuse
b. Body ground
c. Fuel supply
a. Fuel line
b. Fuel filter
c. Fuel pump
d. Ignition system
a. Spark plug
b. High-tension cable
c. Ignition coil
e. Emission control system
a. PCV system
b. Vacuum leak
f. Others
a. Ignition timing
b. Idle speed

TROUBLESHOOTING GUIDE CHART

The number herein means the check order.
 2004 > 1.8L DOHC >

SPECIFICATIONS
Items Specifications
FUEL SYSTEM
Fuel Tank Capacity (Liter) 55
Fuel Filter Type High Pressure Type
(Built in Fuel Pump Assembly)
Fuel Pressure Regulator Built in Fuel Pump Assembly
Regulator Pressure 324kpa (3.3 kg/cm², 47 psi)
Fuel Pump Electrical, in-tank type
INPUT SENSORS
Mass Air Flow Sensor (MAF) Type Hot Film Type
Output Voltage (V) 0-5V
Throttle Position Sensor (TPS) Type Variable Resister Type
Resistance (Ω) 1.6 - 2.4Ω
Output Voltage (V) 0.4 - 0.6V at IDLE
4.1 - 4.3V at Wide Open Throttle
Knock Sensor Type Piezoelectric Type
Intake Air Temperature Sensor (IAT) Type Thermistor Type (Built in AFS sensor)
Output Voltage (V) 3.54V at 20°C (68°F)
Water Temperature Sensor (WTS) Type Thermistor Type
Resistance (Ω) 2.31 - 2.59kΩ at 20°C (68°F)
0.322kΩ at 80°C (176°F)
Heated Oxygen Sensor (HO2S) Type Zirconia Sensor (Heated)
Output Voltage (V) 0 - 1V
Vehicle Speed Sensor Type Wheel Speed Sensor
Camshaft Position Sensor (TDC Type Hall Effect Sensor
Sensor)
Output Voltage (V) 0 - 24V
Crankshaft Position Sensor (CKP
Type Magnetic Inductive Type
Sensor)
Acceleration Sensor Type Piezoelectric type
OUTPUT ACTUATORS
Injector Type Electromagnetic type
Number 4
Coil Resistance (Ω) 13.8 - 15.2 Ω
EVAP Canister Purge Solenoid Valve Type Duty type
Resistance (Ω) 26Ω
Idle Speed Control Actuator (ISA ) Type Double Coil Type
Coil Resistance (Ω) Close : 17.6 ± 1Ω at 20°C (68°F)
Open : 15.5 ± 1Ω at 20°C (68°F)
 SERVICE STANDARD
Items A6 DOHC T8 DOHC
Basic idle rpm 800 ± 50 800 ± 50
Ignition timing BTDC 6° ± 10° BTDC 5° ± 10°

SEALANT

Water temperature sensor assembly LOCTITE 962T or equivalent

Water temperature sender Three bond No.2310 or equivalent

TIGHTENING TORQUE

Items N·m lb·ft

Delivery pipe installation bolts 10 - 15 7 - 11
Heated oxygen sensor 29 - 49 21.4 - 36.1
Crankshaft position sensor installation bolts 9 - 11 6.6 -8.1
Knock sensor installation bolt 15 - 25 11.0 - 18.4
Throttle position sensor installation bolts 1.5 - 2.5 1.1 - 1.8
Water Temperature Sensor installation (A6
24.5 - 29.4 18.1 - 21.7
DOHC)
Water Temperature Sensor installation (T8
19.6 - 39.2 14.5 - 28.9
DOHC)
Acceleration Sensor Installation 2.5 1.84
TDC Sensor Installation 8.8 - 9.8 6.5 - 7.2
Engine Control System
Fuel Pump Relay
 2004 > 1.8L DOHC >

FUEL PUMP RELAY INSPECTION

Check operation

The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.

Listen for fuel pump relay clicking as ignition switch is turned "ON".

Continuity inspection
Terminal 85-86 Terminal 87-30
Apply B+ and ground Continuity
B+ and ground not applied No Continuity

REMOVAL

Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work
area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible.

1. Release fuel system pressure. Refer to "Releasing fuel system pressure".

2. Disconnect negative battery cable.
3. Remove rear seat cushion.
4. Disconnect fuel delivery module connectors.
5. Remove three screws attaching access cover.

6. Remove rubber grommet and wires from access cover and remove access cover.
7. Disconnect two fuel hoses from to fuel delivery module.
8. Remove six screws attaching fuel delivery module and remove fuel delivery module from fuel tank.

INSTALLATION
1. Install fuel delivery module and tighten six screws.

Tightening torque:
7.7~12.2 lb·ft (10.8~16.7 N·m, 1.1~1.7 kg·m)

2. Reconnect two fuel hoses to fuel delivery module.

3. Install rubber grommet and wire onto access cover.
4. Install access cover and tighten three screws for access cover.

Tightening torque:
7.7~12.2 lb·ft (10.8~16.7 N·m, 1.1~1.7 kg·m)

5. Reconnect one connectors to fuel delivery module.

6. Position wires and secure to floor with tape.
7. Install rear seat cushion.
8. Connect negative battery cable.
 2004 > 1.8L DOHC >

MFI SYSTEM INSPECTION

a. Engine is hard to start or does not start at all.
b. Unstable idle.
c. Poor driveability

a. Before removing or installing any part, read the diagnostic trouble codes and then disconnect the battery
negative (-) terminal.
b. Before disconnecting the cable from battery terminal, turn the ignition switch to OFF. Removal or connection
of the battery cable during engine operation or while the ignition switch is ON could cause damage to the
ECU.
c. The control harnesses between the ECU and heated oxygen sensor are shielded with the shielded ground
wires to the body in order to prevent the influence of ignition noises and radio interference. When the shielded
wire is faulty, the control harness must be replaced.
d. When checking the generator for the charging state, do not disconnect the battery '+' terminal to prevent the
ECU from damage due to the voltage.
e. When charging the battery with the external charger, disconnect the vehicle side battery terminals to prevent
damage to the ECU.

Malfunction Indicator Lamp (MIL)

a. Catalyst
b. Fuel system
c. Mass Air Flow Sensor
d. Intake Air Temperature Sensor
e. Water Temperature Sensor
f. Throttle Position Sensor
g. Upstream Oxygen Sensor
h. Downstream Oxygen Sensor Heater
i. Downstream Oxygen Sensor
j. Upstream Oxygen Sensor Heater
k. Injector
l. Misfire
m. Crankshaft Position Sensor
n. Camshaft Position Sensor
o. Evaporative Emission Control System
p. Vehicle Speed Sensor
q. Idle Control Valve
r. Power Supply
s. ECU
t. MT/AT Encoding
u. Acceleration Sensor
v. MIL-on Request Signal
w. Power Stage
a. Heated oxygen sensor (HO2S)
b. Mass Air Flow sensor (MAF)
c. Throttle position sensor (TPS)
d. Engine coolant temperature sensor (WTS)
e. Idle speed control actuator (ISA)
f. Injectors
g. ECU

[INSPECTION]
a. After turning ON the ignition key, ensure that the light illuminates for about 5 seconds and then goes out.
b. If the light does not illuminate, check for an open circuit in the harness, a blown fuse or a blown bulb.

Self-Diagnosis

If a sensor connector is disconnected with the ignition switch turned on, the diagnostic trouble code (DTC) is
recorded. In this case, disconnect the battery negative terminal (-) for 15 seconds or more, and the diagnosis
memory will be erased.

THE RELATION BETWEEN DTC AND DRIVING PATTERN IN EOBD SYSTEM

a. When the same malfunction is detected and maintained during two sequential driving cycles, the MIL will
automatically illuminate.
b. The MIL will go off automatically if no fault is detected after 3 sequential driving cycles.
c. A Diagnostic Trouble Code(DTC) is recorded in ECU memory when a malfunction is detected after two sequential
driving cycles. The MIL will illuminate when the malfunction is detected on the second driving cycle.
If a misfire is detected, a DTC will be recorded, and the MIL will illuminate, immediately after a fault is first
detected.
d. A diagnostic Trouble Code(DTC) will automatically erase from ECU memory if the same malfunction is not detected
for 40 driving cycles.

a. A "warm-up cycle" means sufficient vehicle operation such that the coolant temperature has risen by at least
40 degrees Fahrenheit from engine starting and reaches a minimum temperature of 160 degress Fahrenheit.
b. A "driving cycle" consists of engine startup, vehicle operation beyond the beginning of closed loop operation.
2004 > 1.8L DOHC >

MASS AIR FLOW SENSOR (MAF)

Circuit Diagram

TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING HINTS
a. If the engine stalls occasionally, start the engine and shake the MAF sensor harness. If the engine stalls, check
for poor contact at the MAF sensor connector.
b. If the MAF sensor output voltage is other than 0 when the ignition switch is turned on (do not start the engine).
Check for a faulty MAF sensor or ECU.
c. If the engine can be idle even if the MAF sensor output voltage is out of specification, check for the following
conditions;
a. Disturbed air flow to the MAF sensor, check for disconnected air duct, and clogged air cleaner filter.
b. Poor combustion in the cylinder, check for faulty ignition plug, ignition coil, injector, and incorrect comparison.
d. Check the mounting direction of AFS.
Air Flow (kg/h) Output Voltage (V)
167.20 0.0
259.60 2.314
350.80 3.115
440.60 3.583
480.00 3.751
624.00 4.200
804.70 4.609
894.20 4.775
988.10 4.931
1024.30 4.990
 a. When the vehicle is new [within initial operation of about 500 km (300 miles)], the mass air flow sensor air
quantity will be about 10% higher.
b. Use an accurate digital voltmeter.
c. Before checking, warm up the engine until the engine coolant temperature reaches 80 to 90°C (176 to
198°F)

HARNESS INSPECTION PROCEDURE

INTAKE AIR TEMPERATURE SENSOR (IAT)

Circuit Diagram
TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING HINTS
a. When the intake air temperature is detected as below -40°C (-40°F) or higher than 120°C (248°F)
b. Input from intake air temperature sensor is below 0.1V or above 4.8V when engine is in a full warm-up condition.
USING HI-SCAN

Check item Data display Check conditions Intake air temperature Test specification
Intake air Air temperature Ignition switch : When -20°C (-4°F) -20°C (-4°F)
temperature sensor ON or engine
When 0°C (32°F) 0°C (32°F)
running
When 20°C (68°F) 20°C (68°F)
When 40°C (104°F) 40°C (104°F)
When 80°C (176°F) 80°C (176°F)

HARNESS INSPECTION PROCEDURE

SENSOR INSPECTION
1. Use the multimeter, measure the sensor output voltage.
2. Measure the resistance between the IAT sensor terminal 1 and 4.

IG ON Temperature [°C (°F)] Output voltage (V)

120 (248) 0.57
100 (212) 0.84
80 (176) 1.27
60 (140) 1.89
40 (104) 2.70
20 (68) 3.54
0 (32) 4.24
-20 (-4) 4.67
-40 (-40) 4.89

3. If the resistance deviates from the standard value, replace the intake air temperature sensor assembly.

WATER TEMPERATURE SENSOR (WTS)

CIRCUIT DIAGRAM
USING HI-SCAN (Pro)

Check item Data display Check conditions Intake air temperature Test specification
Engine coolant Sensor Ignition switch : When -20°C (-4°F) -20°C (-4°F)
temperature temperature ON or engine
When 0°C (32°F) 0°C (32°F)
sensor running
When 20°C (68°F) 20°C (68°F)
When 40°C (104°F) 40°C (104°F)
When 80°C (176°F) 80°C (176°F)

HARNESS INSPECTION PROCEDURES

SENSOR INSPECTION
1. Remove the engine coolant temperature sensor from the intake manifold.
2. With the temperature sensing portion of the engine coolant temperature sensor immersed in hot water, check
resistance.
WTS

Temperature [°C (°F)] Resistance (kΩ)

 -40 (-40) 48.14
-20 (-4) 14.13 - 16.83
0 (32) 5.790
20 (68) 2.31 - 2.59
40 (104) 1.148
60 (140) 0.586
80 (176) 0.322
100 (212) 0.1884
110 (230) 0.1451 - 0.1491
120 (248) 0.1163

GAUGE UNIT
Temperature [°C (°F)] Resistance (Ω)
60 (104) 125
85 (185) 42.6 - 54.2
110 (230) 22.1 - 26.2
125 (257) 15.2

3. If the resistance deviates from the standard value greatly, replace the sensor.

INSTALLATION
1. Apply sealant LOCTITE 962T or equivalent to threaded portion.
2. Install water temperature sensor and tighten it to specified torque.

Tightening torque
Water temperature sensor :
20-40 N·m (2.0-4.0 kg·m, 14.8-29.5 lb·ft)

3. Connect the harness connector securely.

THROTTLE POSITION SENSOR (TPS)

 CIRCUIT DIAGRAM

TROUBLESHOOTING HINTS
a. The TPS signal is important for the control of automatic transaxles. Shift shock and other trouble may occur if the
sensor is faulty.
b. If engine idle or acceleration is abnormal, check the TPS connector. (When the TPS connector is not connected
properly,the current data on HI-SCAN (Pro) can show that the idle state remains off, although the accelerator
pedal is released. This results in the improper idle or acceleration.)
c. Input voltage from throttle position sensor is below 0.25V or above 4.7V when ignition switch is turned on.
USING VOLTMETER OR HI-SCAN (Pro)

Check item Check condition Test specification

Throttle position sensor output voltage At idle rpm 0.4 - 0.6V
Wide open throttle 4.1 - 4.3V

HARNESS INSPECTION PROCEDURES

SENSOR INSPECTION
1. Disconnect the throttle position sensor connector.
2. Measure the resistance between terminals 1 (sensor ground) and terminal 2 (sensor power).

Standard value : 1.6 - 2.4 kΩ

3. Connect an analog ohmmeter between terminals 2 (sensor ground) and terminal 3 (sensor output).
4. Operate the throttle valve slowly from the idle position to the full open position, and check that the resistance
changes smoothly in proportion with the throttle valve opening angle.
5. If the resistance is out of specification, or fails to change smoothly, replace the throttle position sensor.

Tightening torque
Throttle position sensor :
1.5-2.5 N·m (0.15-0.25 kg·m, 1.1-1.8 lb·ft)

CAMSHAFT POSITION SENSOR (TDC)

CIRCUIT DIAGRAM
HARNESS INSPECTION PROCEDURES
CRANKSHAFT POSITION SENSOR (CKP)

CIRCUIT DIAGRAM

HARNESS INSPECTION PROCEDURES

SENSOR INSPECTION
1. Disconnect the crankshaft position sensor connector.
2. Measure the resistance between terminals 1 and 2.

Standard value : 0.77-0.95 kΩ at 20°C (68°F)

3. If the resistance deviates far from the standard value, replace the sensor.

Standard value
Clearance between the crankshaft position sensor and crankshaft position sensor wheel :
1.8 mm (0.0709 inch)

Tightening torque
Crankshaft position sensor :
9-11 N·m (9-11 kg·m, 6.6-8.1 lb·ft)
 HEATED OXYGEN SENSOR (HO2S)

a. HO2S (Bank 1, Sensor 2) is located near UCC.

CIRCUIT DIAGRAM

TROUBLESHOOTING HINTS
a. If the heated oxygen sensor is defective, abnormally high emissions may occur.
b. If the heated oxygen sensor check is normal but the sensor output voltage is out of specification, check for the
following items related to the air fuel ratio control system:
a. Faulty injector.
b. Air leaks in the intake manifold.
c. Faulty mass air flow sensor, purge valve and engine coolant temperature sensor.
d. Wiring connection problem.
USING VOLTMETER/HI-SCAN (Pro)

Check item Check condition Engine condition Test specification

Heated oxygen sensor output Warm-up When decelerating suddenly A. 200mV or lower
voltage from 4,000 rpm
When engine is suddenly B. 600-1,000mV
raced
 If you release the accelerator pedal suddenly after engine running about 4000 rpm, fuel supply will stop for short
period and the O₂sensor service data in the HI-SCAN (Pro) will display values 200mV or lower.
When you suddenly press on the accelerator pedal down, the voltage will reach 600-1000mV.
When you let the engine idle again, the voltage will fluctuate between 200mV or lower and 600-1000mV.
In this case, the O₂sensor can be determined as good.

HARNESS INSPECTION PROCEDURES

SENSOR INSPECTION

a. Before checking, warm up the engine until the engine coolant temperature reaches 80 to 95°C (176 to 205°F).
b. Use an accurate digital voltmeter.
 INJECTOR

CIRCUIT DIAGRAM

TROUBLESHOOTING HINTS
a. If the engine is difficult to start when it is hot, check for low fuel pressure and injector leaks.
b. If the injector does not operate when the engine is cranked, then check the following:
a. Faulty power supply circuit to the ECU or faulty ground circuit.
b. Faulty MFI control relay.
c. Faulty crankshaft position sensor or camshaft position sensor.
c. If engine idle remains unchanged when fuel injection to the cylinders is cut one after another, check for the
following items about such cylinder:
a. Injector and harness.
b. Spark plug and high tension cable.
c. Compression pressure.
d. If the injection system is OK but the injector's pulse width is out of specification, check for the following items:
a. Poor combustion in the cylinder (faulty spark plug, ignition coil, compression pressure, etc.)
e. The MIL is on or the DTC is displayed on the HI-SCAN (Pro) under the following condition:
a. When the injector itself is faulty
USING HI-SCAN (Pro)

Check item Data display Check conditions Engine state Test specification
Injector Drive time a. Engine coolant temperature: 80 Idle rpm 1.5 - 4.5 ms
 to 95°C (176 to 205°F) 2000 rpm
b. Lamps, electric cooling fan,
accessory units: ALL OFF 3000 rpm
c. Transaxle : Neutral (P range for
vehicle with A/T) Racing Increasing
d. Steering wheel : Neutral

Check item Check condition HI-SCAN (Pro) display Type

Injector Start the engine 01. No.1 Injector Activate
a. Actuator test 02. No.2 Injector Activate
03. No.3 Injector Activate
04. No.4 Injector Activate

HARNESS INSPECTION PROCEDURES

INJECTOR INSPECTION
a. Activate the fuel injectors in sequence.
b. Check the pulse width of the injectors.
a. Using a stethoscope, check the injectors for a clicking sound at idle. Check that the sound is produced at shorter
intervals as the engine speed increases.
 Ensure that the sound from an adjacent injector is not being transmitted along the delivery pipe to an
inoperative injector.

b. If a stethoscope is not available, check the injector operation with your finger.
If no vibrations are felt, check the wiring connector, injector, or injection signal from ECU.

a. Disconnect the connector at the injector and measure the resistance between the two terminals.

Standard value : 13.8 - 15.2 Ω [at 20°C (68°F)]

b. Re-connect the connector to the injector.

IDLE SPEED CONTROL ACTUATOR (ISA)

CIRCUIT DIAGRAM
TROUBLESHOOTING HINTS
USING HI-SCAN (Pro)

Check item Check condition ISA condition Test specification

Idle speed control actuator Start the engine ON Activate
a. Actuator test

HARNESS INSPECTION PROCEDURES

ACTUATOR INSPECTION
1. Disconnect the connector at the idle speed control actuator.
2. Measure the resistance between terminals.
 Standard value
Terminal 1-2 (close) : 17.6±1Ω at 20°C(68°F)
Terminal 3-2 (open): 15.5±1Ω at 20°C(68°F)

3. Connect the connector to the idle speed control actuator.

KNOCK SENSOR

CIRCUIT DIAGRAM
SENSOR INSPECTION
1. Disconnect the knock sensor connector and measure resistance between terminals 1 and 2.

Standard value : 4.38-5.36 MΩ at 20°C (68°F)

2. If the resistance is continuous, replace the knock sensor.

Tightening torque
Knock sensor :
15-25 N·m (1.5 kg·m, 11.0-18.4 lb·ft)

3. Measure the capacitance between terminals 1 and 2.

Standard value : 800 - 1600 pF

ENGINE CONTROL UNIT (ECU)-POWER GROUND

CIRCUIT DIAGRAM

HARNESS INSPECTION PROCEDURE

EVAPORATIVE EMISSION CANISTER PURGE SOLENOID VALVE

 CIRCUIT DIAGRAM

USING HI-SCAN (Pro)

Check item Check condition HI-SCAN (Pro) display Type

Evaporative emission Start the engine PURGE VALVE Activate
canister purge solenoid
valve
a. Actuator test

HARNESS INSPECTION PROCEDURES

IGNITION COIL

CIRCUIT DIAGRAM

HARNESS INSPECTION PROCEDURES

 ACCELERATION SENSOR
CIRCUIT DIAGRAM

USING VOLTMETER

Check item Check condition Test specification

Acceleration sensor output voltage While idling 2.3 - 2.7V
While driving 1.5 - 3.5V

HARNESS INSPECTION PROCEDURES

Fuel Delivery System
Fuel Tank
 2004 > 1.8L DOHC >

REMOVAL

Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work
area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible.
Drain the fuel from the fuel tank before removing the tank.

1. Release fuel system pressure. Refer to "Releasing fuel system pressure".

2. Disconnect negative battery cable.
3. Remove rear seat cushion.
4. Disconnect fuel delivery module connectors.
5. Remove three screws attaching access cover.

6. Remove rubber grommet and wires from access cover.

7. Remove access cover.

8. Remove two fuel hose quick connectors from fuel delivery module.
9. Raise the vehicle.
10. Position a lifting device below center of fuel tank.
11. Disconnect two fuel hose quick connector attached to fuel filter.
12. Disconnect fuel vapor hose attached to two way check valve.
13. Loosen one joint hose clamp attached to fuel tank.
14. Disconnect joint hose from fuel tank.
15. Disconnect bolts attaching insulator and insulator.
16. Remove two bolts attaching fuel tank straps and remove fuel tank straps.

Cover the open ports on the fuel tank with plastic caps or other available covers to avoid fuel vapor
contaminating the work area.
17. Remove fuel tank from vehicle.

INSTALLATION

Fuel is explosive. An empty fuel tank can still contain explosive gases. Supply adequate ventilation to the work
area. Do not smoke and keep sparks and open flames away. Purge fumes from the tank as soon as possible.

1. Raise the vehicle.

2. Remove protective caps from fuel tank ports.
3. Place fuel tank on lifting device and carefully raise fuel tank assembly into correct position.
4. Reconnect joint hose to fuel tank and tighten clamp.
5. Reconnect two fuel hoses to fuel tank.

Push evaporative hose onto fuel tank fitting at least 1.0 inch (25.4 mm). Push fuel filler hoses onto fuel tank
and filler pipes at least 1.4 in (35.6 mm).

6. Install fuel tank straps.

7. Install and Tighten two bolts for fuel tank straps.

Tightening torque:
32~44 lb·ft (43~61 N·m, 440~660 kg·cm)

8. Install insulator and tighten bolts.

9. Lower vehicle.
10. Reconnect two fuel hoses to fuel delivery module.
11. Install rubber grommet and wires onto access cover.

12. Install access cover and tighten three screws.

Tightening torque:
7.7~12.2 lb·ft (10.8~16.7 N·m, 1.1~1.9 kg·m)
13. Reconnect connector to fuel delivery module.

14. Position wires correctly and secure to floor with tape.

15. Reinstall rear seat cushion.
16. Reconnect negative battery cable.
Fuel Pump
 2004 > 1.8L DOHC >

INSPECTION

The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.

FUEL PUMP OPERATION

1. Connect data link connector terminals FUEL PUMP and B+ with jumper wire.

2. Remove fuel filler cap.

3. Turn ignition switch "ON".
4. Determine if fuel pump is running by listening for sound of it at fuel filler inlet.
5. Install fuel filler cap.
6. If no sound was heard, measure voltage between fuel pump connector wire to chassis ground.

Voltage: Approx. 12V

7. If voltage is not correct, check fuel pump relay and related wiring harness.
8. If you do not measure 12V, check for continuity between fuel pump connector terminal wires.
9. If there is continuity, replace fuel delivery module.
10. If there is no continuity, repair ground circuit.

FUEL PUMP MAXIMUM PRESSURE

1. Disconnect negative battery terminal.
2. Release fuel system pressure. Refer to "Releasing fuel system pressure".
3. Raise a vehicle.
4. to fuel filter and close the valve in line to fuel filter as shown.
5. Connect negative battery terminal.

The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.

6. Connect data link connect terminals FUEL PUMP and B+ with jumper wire.

7. Turn ignition switch ON.

8. Measure fuel pump maximum pressure.

Fuel pump maximum pressure:

65~94 psi (450~650 kPa, 4.5~6.5 kg/cm²)

9. If not within specification, replace fuel delivery module.

Fuel Filter
 2004 > 1.8L DOHC >

REMOVAL

Fuel is explosive. When working on fuel system make sure to supply adequate ventilation to the work area. Do
not smoke, and keep sparks and open flames away.

1. Depressurize fuel system. Refer to "Releasing fuel system pressure".

2. Disconnect fuel hoses from fuel filter.
3. Remove fuel filter and bracket.

INSTALLATION
1. Install fuel filter and bracket.

Tightening torque:
9.5 lb·ft (12.9 N·m, 1.3 kg·m)

2. Connect fuel hoses.

Fuel Line
 2004 > 1.8L DOHC >

REMOVAL

Fuel is explosive. When working on fuel system make sure to supply adequate ventilation to the work area. Do
not smoke, and keep sparks and open flames away.

It may be necessary to remove other chassis brackets in order to gain access to fuel lines. If this is necessary, Refer
to the appropriate sections for removal procedures.
1. Disconnect negative terminal from battery cable.
2. Loosen six retaining bracket screws and remove two fuel lines from each bracket, one at a time, until two fuel lines
are free from brackets.
3. Loosen fittings at ends of fuel lines and carefully slide lines through undercarriage of vehicle chassis until they can
be fully taken away from fixtures by taking off fastening clips.

REMOVAL (FUEL FILLER PIPE)

Fuel is explosive. When working on fuel system make sure to supply adequate ventilation to the work area. Do
not smoke, and keep sparks and open flames away.

1. Open fuel filler door.

2. Remove filler cap.
3. Remove two upper mounting screws from fuel filler pipe assembly.
4. Remove two bolts and two fasteners and remove splash shield from left rear wheel well.

5. Raise the vehicle.

6. Remove two bolts from attaching fuel filler pipe assembly to vehicle sub-frame.
7. Loosen clamps and remove fuel filler pipe assembly from joint hose.

INSTALLATION
 Fuel is explosive. When working on fuel system, make sure to supply adequate ventilation to the work area. Do
not smoke, and keep sparks and open flames away.

It may be necessary for transaxle assembly and other chassis brackets to be removed in order to reinstall fuel lines. If
this is true, refer to appropriate sections for removal and reinstallation procedures.
1. Reinsert fuel lines carefully into each of six retaining brackets along undercarriage of vehicle chassis until all fuel
lines have been properly positioned into place.
2. Tighten six bracket retaining screws.
3. Reconnect fuel lines/hoses.
4. Install clips to fasten fuel lines/hoses to fittings.
5. Connect negative terminal to battery cable.

INSTALLATION (FUEL FILLER PIPE)

Fuel is explosive. When working on fuel system parts, make sure to supply adequate ventilation to the work area.
Do not smoke, and keep sparks and open flames away.

1. Raise the vehicle.

2. Connect fuel filler pipe assembly to joint hose.
3. Install attaching bolts to bracket holding fuel filler pipe assembly to vehicle sub-frame.

Tightening torque:
6.5~9.3 lb·ft (8.8~12.7 N·m, 0.9~1.3 kg·m)

4. Install splash shield and two bolt and two fasteners.

Tightening torque:
7.7~12.2 lb·ft (10.8~16.7 N·m, 1.1~1.7 kg·m)

5. Lower vehicle on hydraulic lift to ground level.

6. Install two upper mounting screws to fuel filler pipe assembly.
 Tightening torque:
1.8~2.5 lb·ft (2.5~3.5 N·m, 0.25~0.36 kg·m)

7. Install filler cap.

8. Close the fuel filler door.

INSPECTION
FUEL PRESSURE HOLD INSPECTION
1. Disconnect negative battery terminal.

The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.

2. Release fuel system pressure. Refer to "Releasing fuel system pressure".

3. Raise the vehicle.
4. to fuel filter as descried below.

5. Connect negative battery terminal.

6. Connect data link connector terminals FUEL PUMP and B+ with jumper wire.

7. Turn ignition switch ON for 10 seconds to operate fuel pump.

8. Turn ignition switch OFF and remove jumper wire.
9. Inspect fuel pressure after 15 minutes.

Fuel pressure:
More than 25 psi (180 kPa, 1.8 kg/cm²)

10. If not as specified, check the following components: do following inspections:

a. Fuel pump
b. Pressure regulator
c. Injectors
FUEL LINE PRESSURE INSPECTION
1. Disconnect negative battery cable.
2. Release fuel system pressure. Refer to "Releasing Fuel System Pressure".
3. Raise the vehicle.
4. to fuel filter as shown.

5. Connect negative battery cable.

6. Connect data link connector terminals FUEL PUMP and B+ with jumper wire.
7. Turn ignition switch ON.
8. Inspect the fuel line pressure.

Fuel line pressure:

46~51 psi (320~350 kPa, 3.2~3.5 kg/cm²)

Pressure too high:

a. Check for restricted fuel return line
b. If line is clean, replace pressure regulator
Pressure too low:
a. Clamp return line and check if pressure rises
b. If pressure does rise, replace pressure regulator
c. If pressure does not rise, measure fuel pump maximum pressure
9. Turn ignition switch OFF and remove jumper wire.
 2004 > 1.8L DOHC >

RELEASING FUEL SYSTEM PRESSURE

The fuel system remains under pressure when the engine is not running. Release fuel system pressure before
disconnecting any fuel line to reduce the chance of personal injury or fire damage to vehicle components.

1. Start engine.
2. Disconnect fuel pump connector located below rear seat cushion.
3. Let engine stall, then turn OFF ignition switch.
4. Reconnect the fuel pump connector.

FUEL LINE HANDLING

Fuel is explosive. When working on fuel system make sure to supply adequate ventilation to the work area. Do
not smoke, and keep sparks and open flames away.

1. When disconnecting the fuel hose quick connectors, use shop towels to absorb fuel, protecting equipment and
personnel.

PRIMING THE FUEL SYSTEM

1. Connect data link connector terminals FUEL PUMP and B+ with a jumper wire.

2. Turn ignition switch ON for no longer than 10 seconds to pressurize system and check for fuel leaks. (Jumper wire
gets hot if it is left in for longer than 10 seconds.)
3. Turn ignition switch OFF and remove jumper wire.