FUEL FILTER REPLACEMENT

PROCEDURE


  1. REMOVE NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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  3. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  4. REMOVE FUEL FILTER ASSEMBLY


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


      1. A012M7SC01
        *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. A012N2XC01
        *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. A012GFY

        Disconnect the connector from the fuel filter assembly.

      2. Remove the 2 nuts and fuel filter assembly.

  5. DRAIN FUEL


    1. A012FHO

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

  6. REMOVE FUEL FILTER GASKET


    1. A012IN6

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

    2. A012FXS

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

  7. REMOVE LEVEL WARNING SWITCH

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  8. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A012N44N01

      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. A012GSD

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

    2. Apply a light coat of fuel 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

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  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. A012GFY

        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. A012LS8C01
        *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. A012GXIC01
        *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. A012FBSC01
        *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. A012M41C01
        *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

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  14. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  15. BLEED AIR FROM FUEL SYSTEM

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  16. INSPECT FOR FUEL LEAK

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  17. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

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