FUEL FILTER REPLACEMENT

PROCEDURE


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


  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


  3. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


  4. REMOVE FUEL FILTER ASSEMBLY


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


      1. A01M1WFC01
        *A w/o Glow Plug Controller
        *B w/ Glow Plug Controller
        *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 from the fuel filter assembly.

      2. Slide the clip and disconnect the No. 2 fuel hose from the fuel filter assembly.

      3. Slide the clip and disconnect the No. 1 fuel hose from the fuel filter assembly.

      4. Slide the clip and disconnect the No. 4 fuel hose from the fuel filter assembly.

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


      1. A01LWWJC01
        *A w/o Glow Plug Controller
        *B w/ Glow Plug Controller
        *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 from the fuel filter assembly.

      2. Slide the clip and disconnect the No. 2 fuel hose from the fuel filter assembly.

      3. Slide the clip and disconnect the No. 1 fuel hose from the fuel filter assembly.

      4. Slide the clip and disconnect the No. 4 fuel hose from the fuel filter assembly.

      5. Slide the clip and disconnect the heater fuel hose from the fuel filter assembly.

    3. Remove the fuel filter assembly.


      1. A01LZ4K

        Disconnect the level warning switch connector.

      2. Remove the 2 nuts and fuel filter assembly.

  5. DRAIN FUEL


    1. A01LW0B

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

  6. REMOVE FUEL FILTER GASKET


    1. A01LWU7

      Disengage the 2 clamps to disconnect the wire harness from the fuel filter cap assembly.

    2. A01LYR7

      Disengage the clamp and remove the bolt, nut, fuel filter cover and fuel filter gasket from the fuel filter assembly.

  7. REMOVE LEVEL WARNING SWITCH

    Click here

  8. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A01M36BN01

      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. A01LXAM

      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

    Click here

  11. INSTALL FUEL FILTER GASKET


    1. Engage the clamp and install the fuel filter gasket and fuel filter cover to the fuel filter assembly with the bolt and nut.

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

    2. Engage the 2 clamps to connect the wire harness to the fuel filter cap assembly.

  12. INSTALL FUEL FILTER ASSEMBLY


    1. Install the fuel filter assembly.


      1. 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. 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.

        A01LWOQC01
        *A w/o Glow Plug Controller *B w/ Glow Plug Controller
        *1 No. 1 Fuel Hose *2 No. 2 Fuel Hose
        *3 No. 3 Fuel Hose - -
        *a Mark *b 90°
        *c 120° *d 1 to 5 mm (0.0394 to 0.197 in.)

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

        A01M36HC01
        *A w/o Glow Plug Controller *B w/ Glow Plug Controller
        *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.)

        Tech Tips

        Engage the clip within the area shown in the illustration.

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


      1. 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.

        A01LVS1C01
        *A w/o Glow Plug Controller *B w/ Glow Plug Controller
        *1 No. 1 Fuel Hose *2 No. 2 Fuel Hose
        *3 No. 3 Fuel Hose *4 Heater Fuel Hose
        *a Mark *b 90°
        *c 120° *d 1 to 5 mm (0.0394 to 0.197 in.)

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

        A01M24WC01
        *A w/o Glow Plug Controller *B w/ Glow Plug Controller
        *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.)

        Tech Tips

        Engage the clip within the area shown in the illustration.

  13. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


  14. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


  15. BLEED AIR FROM FUEL SYSTEM

    Click here

  16. INSPECT FOR FUEL LEAK


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