FUEL FILTER REPLACEMENT

CAUTION / NOTICE / HINT

Note

When working on the fuel circuit, protect the generator assembly against contamination. Cover the generator assembly with suitable materials. Failure to comply with this procedure may result in a generator assembly malfunction.

PROCEDURE


  1. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  2. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  3. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  4. REMOVE NO. 1 FUEL FILTER PROTECTOR (w/ Fuel Heater Relay)


    1. B0042HQ

      Disconnect the level warning switch connector.

    2. B0041VV

      Disengage the 4 clamps to disconnect the level warning switch connector from the No. 1 fuel filter protector.

    3. B004352

      Remove the 2 nuts and No. 1 fuel filter protector.

  5. REMOVE NO. 1 FUEL FILTER PROTECTOR (w/o Fuel Heater Relay)


    1. B0043B7

      Remove the 2 nuts and No. 1 fuel filter protector.

  6. REMOVE FUEL FILTER ASSEMBLY (w/ Fuel Heater Relay)


    1. B0043ML

      Remove the No. 2 fuel pipe clamp from the No. 1 fuel hose.

    2. B0043IFC01
      *1 No. 1 Fuel Hose
      *2 No. 3 Fuel Hose

      Disconnect the No. 1 fuel hose and No. 3 fuel hose from the fuel filter assembly.

      Click here

    3. B0044MR

      Disconnect the fuel filter assembly connector.

    4. Remove the nut and fuel filter assembly from the fuel filter support.

    5. B0043ZU

      Remove the bolt and fuel filter cover from the fuel filter assembly.

  7. REMOVE FUEL FILTER ASSEMBLY (w/o Fuel Heater Relay)


    1. B0044K8C01
      *1 No. 2 Fuel Pipe Clamp
      *2 No. 3 Fuel Pipe Clamp

      Remove the No. 2 fuel pipe clamp and No. 3 fuel pipe clamp from the No. 1 fuel hose and No. 3 fuel hose.

    2. B0042G6C01
      *1 No. 1 Fuel Hose
      *2 No. 3 Fuel Hose

      Disconnect the No. 1 fuel hose and No. 3 fuel hose from the fuel filter assembly.

      Click here

    3. B0043F7

      Disconnect the fuel filter assembly connector.

    4. Remove the nut and fuel filter assembly from the fuel filter support.

    5. B0042GC

      Remove the bolt and fuel filter cover from the fuel filter assembly.

  8. DRAIN FUEL (w/ Fuel Heater Relay)


    1. B004200

      Loosen the drain cock and drain the fuel from the fuel filter assembly.

    2. B004471

      Remove the O-ring from the drain cock.

    3. Tighten the drain cock.

      Torque:
      3.1 N*m  { 32 kgf*cm, 27 in.*lbf }

  9. DRAIN FUEL (w/o Fuel Heater Relay)


    1. Loosen the drain cock and drain the fuel from the fuel filter assembly.

  10. REMOVE FUEL FILTER ELEMENT ASSEMBLY (w/ Fuel Heater Relay)


    1. B0041OXN01

      Secure the fuel filter assembly in a vice between aluminum plates.

    2. Using SST, remove the fuel filter case from the fuel filter cap.

      SST
      09228-64010

      Note

      Be careful not to damage the fuel filter cap.

    3. Remove the fuel filter cap from the vice.

    4. B0041US

      Remove the O-ring from the fuel filter cap.

    5. Remove the fuel filter element assembly from the fuel filter case.

  11. INSTALL FUEL FILTER ELEMENT ASSEMBLY (w/ Fuel Heater Relay)


    1. Check and clean the installation surface of the fuel filter case and fuel filter cap.

    2. Apply fuel to the O-ring of a new fuel filter cap.

    3. Install a new fuel filter element assembly to the fuel filter case.

    4. B0041OXN01

      Secure the fuel filter cap in the vice between aluminum plates.

    5. Using SST, install the fuel filter case to the fuel filter cap.

      SST
      09228-64010
    6. B0042X1

      Align the mark on the fuel filter cap and fuel filter case.

    7. Remove the fuel filter assembly from the vice.

  12. INSTALL FUEL FILTER ASSEMBLY (w/ Fuel Heater Relay)


    1. B00437EC02
      *a Protrusion

      Press the protrusion of the fuel filter cover against the fuel filter case.

    2. B0044DD

      Align the mark on the fuel filter cap, fuel filter cover and the fuel filter case.

    3. Install the fuel filter cover to the fuel filter assembly with the bolt.

      Torque:
      12.5 N*m  { 127 kgf*cm, 111 in.*lbf }

    4. Install the fuel filter assembly to the fuel filter support with the nut.

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

    5. Connect the fuel filter assembly connector.

    6. Connect the No. 1 fuel hose and No. 3 fuel hose to the fuel filter assembly.

      Click here

    7. Install the No. 2 fuel pipe clamp to the No. 1 fuel hose.

  13. INSTALL FUEL FILTER ASSEMBLY (w/o Fuel Heater Relay)


    1. Install the fuel filter cover to a new fuel filter assembly with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the fuel filter assembly to the fuel filter support with the nut.

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

    3. Connect the fuel filter assembly connector.

    4. Connect the No. 1 fuel hose and No. 3 fuel hose to the fuel filter assembly.

      Click here

    5. Install the No. 2 fuel pipe clamp and No. 3 fuel pipe clamp to the No. 1 fuel hose and No. 3 fuel hose.

  14. INSTALL NO. 1 FUEL FILTER PROTECTOR (w/ Fuel Heater Relay)


    1. Install the No. 1 fuel filter protector with the 2 nuts.

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

    2. Engage the 4 clamps to connect the level warning switch connector to the No. 1 fuel filter protector.

    3. Connect the level warning switch connector.

  15. INSTALL NO. 1 FUEL FILTER PROTECTOR (w/o Fuel Heater Relay)


    1. Install the No. 1 fuel filter protector with the 2 nuts.

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

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  19. INSPECT FOR FUEL LEAK

    Click here