FUEL FILTER REPLACEMENT

Tech Tips

If replacing only the fuel filter element sub-assembly, steps 2 through 5 are not necessary.


  1. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A01CIPB

      Disconnect the level warning switch connector.

    2. Place a drain pan under the filter.

    3. A01CGOR

      Loosen the drain plug and the air bleed plug as shown in the illustration. Drain the fuel.

      Note


      • Do not use any tools.

      • Do not allow any fuel to spill.

      • If any fuel spills on any part of the engine, wipe it clean with a shop rag or a piece of cloth.

    4. A01CHBS

      When fuel stops draining from the drain plug, tighten the drain plug and air bleed plug.

      Note

      Do not use any tools.

    5. A01CHGGE03
      Text in Illustration
      *1 Fuel Filter Case
      *2 Claw
      *a Turn

      Disengage the claw. Remove the fuel filter case by turning it counterclockwise approximately 120°.

    6. A01CHYJE03
      Text in Illustration
      *1 Fuel Filter Element Sub-assembly
      *2 O-ring
      *3 Fuel Filter Case

      Remove the fuel filter element sub-assembly.

    7. Remove the O-ring from the fuel filter case.

  2. REMOVE FUEL FILTER ASSEMBLY


    1. A01CJ7E

      Disconnect the fuel heater connector (w/ Heater).

    2. A01CHCL

      Disconnect the 2 fuel hoses.

    3. A01CHJQ

      Remove the 2 bolts and the fuel filter assembly.

  3. REMOVE FUEL PREFILTER ASSEMBLY


    1. A01CJ95

      Loosen the drain plug as shown in the illustration. Drain the fuel.

      Note


      • Do not use any tools.

      • Do not allow any fuel to spill.

      • If any fuel spills on any part of the engine, wipe it clean with a shop rag or a piece of cloth.

    2. When fuel stops draining from the drain plug, tighten the drain plug.

    3. A01CJ08

      Disconnect the 2 fuel hoses.

    4. A01CJAL

      Remove the 2 bolts and the fuel prefilter assembly.

  4. INSTALL FUEL PREFILTER ASSEMBLY


    1. A01CJAL

      Install the fuel prefilter assembly with the 2 bolts.

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }
    2. A01CJ08

      Connect the 2 fuel hoses.

  5. INSTALL FUEL FILTER ASSEMBLY


    1. A01CHJQ

      Install the fuel filter assembly with the 2 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
    2. A01CHCL

      Connect the 2 fuel hoses.

    3. A01CJ7E

      Connect the fuel heater connector (w/ Heater).

  6. INSTALL FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A01CHYJE04
      Text in Illustration
      *1 Fuel Filter Element Sub-assembly
      *2 O-ring
      *3 Fuel Filter Case

      Install a new fuel filter element sub-assembly to the fuel filter case.

    2. Install a new O-ring to the fuel filter case.

    3. Apply a light coat of fuel to the O-ring of the fuel filter case.

    4. A01CHGGE04
      Text in Illustration
      *1 Fuel Filter Case
      *2 Claw
      *a Turn

      Install the fuel filter case by turning it clockwise until the claw is engaged.

    5. A01CIPB

      Connect the level warning switch connector.

  7. BLEED AIR FROM FUEL SYSTEM


    1. A01CIXH

      Connect the drain hose to the air bleed plug.

    2. Loosen the fuel filter's air bleed plug.

      Note


      • Do not use any tools.

      • Do not allow any fuel to spill.

      • If any fuel spills on any part of the engine, wipe it clean with a piece of cloth.

    3. A01CGRK

      While covering the drain hose with a piece of cloth, press and release the priming pump until the fuel from the drain hose does not have any bubbles.

    4. A01CHZ4

      Tighten the air bleed plug.

      Note

      Do not use any tools.

  8. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop or Start

        • Fuel pressure inside common rail is pressurized to specified value and engine speed is increased to 2000 rpm when Start is selected.

        • Above conditions preserved while Start is selected.