FUEL FILTER REPLACEMENT

PROCEDURE


  1. REMOVE NO. 1 ENGINE COVER

    Click here

  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  3. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  4. REMOVE FUEL FILTER ASSEMBLY


    1. Disconnect the 4 fuel hoses. (w/o Combustion Type Power Heater)


      1. A00YA1KC01
        *1 No. 1 Fuel Hose
        *2 No. 2 Fuel Hose
        *3 No. 3 Fuel Hose
        *4 No. 4 Fuel Hose

        Slide the clip and disconnect the No. 3 fuel hose.

      2. Slide the clip and disconnect the No. 2 fuel hose.

      3. Slide the clip and disconnect the No. 1 fuel hose.

      4. Slide the clip and disconnect the No. 4 fuel hose.

    2. Disconnect the 5 fuel hoses. (w/ Combustion Type Power Heater)


      1. A00YAA8C01
        *1 No. 1 Fuel Hose
        *2 No. 2 Fuel Hose
        *3 No. 3 Fuel Hose
        *4 No. 4 Fuel Hose
        *5 Heater Fuel Hose

        Slide the clip and disconnect the No. 3 fuel hose.

      2. Slide the clip and disconnect the No. 2 fuel hose.

      3. Slide the clip and disconnect the No. 1 fuel hose.

      4. Slide the clip and disconnect the No. 4 fuel hose.

      5. Slide the clip and disconnect the heater fuel hose.

    3. Remove the fuel filter assembly.


      1. A00Y7AI

        Disconnect the connector from the fuel filter assembly.

      2. Remove the 2 nuts and fuel filter assembly.

  5. DRAIN FUEL


    1. A00Y9JF

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

  6. REMOVE FUEL FILTER GASKET


    1. A00Y5AP

      Disconnect the 2 harness clamps from the fuel filter cap assembly.

    2. A00Y9OF

      Disconnect the harness clamp and remove the bolt, nut, fuel filter cover and fuel filter gasket.

  7. REMOVE LEVEL WARNING SWITCH

    Click here

  8. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A00Y8D2N01

      Using SST, remove the fuel filter element sub-assembly.

      SST
      09228-64010

      Note

      Be careful not to damage the fuel filter cap assembly.

  9. INSTALL FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A00Y5T6

      Check and clean the installation surface of the fuel filter element sub-assembly.

    2. Apply a light coat of gasoline to the gasket of a new fuel filter element sub-assembly.

    3. Temporarily install the fuel filter element sub-assembly, and tighten it until the gasket comes into contact with the seat.

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

  10. INSTALL LEVEL WARNING SWITCH

    Click here

  11. INSTALL FUEL FILTER GASKET


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

    2. Tighten the bolt and nut, and connect the harness clamp to the fuel filter cover.

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

  12. INSTALL FUEL FILTER ASSEMBLY


    1. Install the fuel filter assembly.


      1. A00Y7AI

        Install the fuel filter assembly with the 2 nuts.

        Torque:
        17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      2. Connect the level warning switch connector.

    2. Connect the 4 fuel hoses. (w/o Combustion Type Power Heater)


      1. A00YASHC01
        *1 No. 1 Fuel Hose
        *2 No. 2 Fuel Hose
        *3 No. 3 Fuel Hose
        *a Mark
        *b 90°
        *c 1 to 5 mm (0.0394 to 0.197 in.)

        Connect the No. 1 fuel hose, No. 2 fuel hose and No. 3 fuel hose to the fuel filter assembly, and slide the 3 clips to secure them.

        Note


        • Align the mark and connect each fuel hose.

        • Align the tabs of the clip with the fuel hose mark as shown in the illustration.

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

      2. A00Y6OTC01
        *1 No. 4 Fuel Hose
        *a Front of Vehicle
        *b 105° (Clip Area)
        *c 35°
        *d 1 to 5 mm (0.0394 to 0.197 in.)

        Connect the No. 4 fuel hose to the fuel filter assembly, and slide the clip to secure it.

        Note

        Engage the clip within the area shown in the illustration.

    3. Connect the 5 fuel hoses. (w/ Combustion Type Power Heater)


      1. A00Y51EC01
        *1 No. 1 Fuel Hose
        *2 No. 2 Fuel Hose
        *3 No. 3 Fuel Hose
        *4 Heater Fuel Hose
        *a Mark
        *b 90°
        *c 1 to 5 mm (0.0394 to 0.197 in.)

        Connect the No. 1 fuel hose, No. 2 fuel hose, No. 3 fuel hose and heater fuel hose to the fuel filter assembly, and slide the 4 clips to secure them.

        Note


        • Align the mark and connect each fuel hose.

        • Align the tabs of the clip with the fuel hose mark as shown in the illustration.

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

      2. A00Y74BC01
        *1 No. 4 Fuel Hose
        *a Front of Vehicle
        *b 105° (Clip Area)
        *c 35°
        *d 1 to 5 mm (0.0394 to 0.197 in.)

        Connect the No. 4 fuel hose to the fuel filter assembly, and slide the clip to secure it.

        Note

        Engage the clip within the area shown in the illustration.

  13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  14. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  15. BLEED AIR FROM FUEL SYSTEM

    Click here

  16. INSPECT FOR FUEL LEAK

    Click here

  17. INSTALL NO. 1 ENGINE COVER

    Click here