FUEL FILTER REPLACEMENT

PROCEDURE


  1. REMOVE NO. 1 ENGINE COVER

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  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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  3. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  5. REMOVE FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)


    1. A004QSN

      Disconnect the 4 fuel hoses.

    2. A004R2N

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  6. REMOVE FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)


    1. A004TL7

      Disconnect the 5 fuel hoses.

    2. A004R2N

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  7. DRAIN FUEL


    1. A004R13

      Loosen the drain bolt and drain the fuel from the fuel filter.

  8. REMOVE FUEL FILTER GASKET


    1. A004NNZ

      Detach the 3 harness clamps.

    2. A004SBV

      Remove the bolt, filter cover and filter gasket.

  9. REMOVE LEVEL WARNING SWITCH

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  10. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY

    A004OHDE01

    1. Using SST, remove the fuel filter element.

      SST
      09228-64010

  11. INSTALL FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A004S2V

      Check and clean the installation surface of the fuel filter.

    2. Apply fuel to the gasket of a new fuel filter element.

    3. Lightly screw the fuel filter element into place, and tighten it until the gasket comes into contact with the seat.

    4. Tighten the fuel filter element an additional 3/4 turn by hand.

  12. INSTALL LEVEL WARNING SWITCH

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  13. INSTALL FUEL FILTER GASKET


    1. Install the filter gasket and filter cover to the fuel filter assembly.

    2. Tighten the bolt.

      Torque:
      3.4 N*m  { 35 kgf*cm, 30 in.*lbf }

    3. Attach the 3 harness clamps.

  14. INSTALL FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)


    1. Install the fuel filter assembly with the 2 nuts.

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

    2. Connect the level warning switch connector.

    3. A004UCWE01
      *1 1 to 5 mm

      Connect the No. 1 fuel hose, No. 2 fuel hose and No. 3 fuel hose.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the claws of the clamp with the hose alignment mark as shown in the illustration.

      • Position the clamp so that the distance from the end of the hose is 1 to 5 mm (0.0394 to 0.197 in.).

    4. A004RKDE01
      *1 Front Side of Vehicle

      Connect the No. 4 fuel hose.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    5. A004MVBE01
      *1 Front Side of Vehicle

      Connect the heater fuel hose.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Make sure the direction of the hose clamp is as shown in the illustration.

  15. INSTALL FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)


    1. Install the fuel filter assembly with the 2 nuts.

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

    2. Connect the level warning switch connector.

    3. A004N8BE01
      *1 1 to 5 mm

      Connect the No. 1 fuel hose, No. 2 fuel hose and No. 3 fuel hose.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the claws of the clamp with the hose alignment mark as shown in the illustration.

      • Position the clamp so that the distance from the end of the hose is 1 to 5 mm (0.0394 to 0.197 in.).

    4. A004Q99E01
      *1 Front Side of Vehicle

      Connect the No. 4 fuel hose.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  19. BLEED AIR FROM FUEL SYSTEM

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  20. INSPECT FOR FUEL LEAK

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  21. INSTALL NO. 1 ENGINE COVER

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