FUEL FILTER REPLACEMENT


  1. REMOVE NO. 1 ENGINE COVER


    1. A003DQW

      Hold the rear of the cover and slowly raise it to detach the clip on the rear of the cover. Continue to raise the cover to detach the 3 clips on the front and side of the cover and remove the cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A00OSNR

      Disconnect the mass air flow meter connector.

    2. Disconnect the No. 2 ventilation hose.

    3. Disconnect the air cleaner hose.

    4. Detach the 4 clamps and remove the air cleaner cap.

  3. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A00OUZE

      Remove the 3 bolts and air cleaner case.

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


    1. A00E6Q8E01

      Disconnect the 4 fuel hoses.

    2. A00E7QY

      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. A00E84F

      Disconnect the 5 fuel hoses.

    2. A00E7QY

      Disconnect the level warning switch connector.

    3. Remove the 2 nuts and fuel filter assembly.

  7. DRAIN FUEL


    1. A00EATH

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

  8. REMOVE FUEL FILTER GASKET


    1. A00E8UC

      Detach the 3 harness clamps.

    2. A00E9OX

      Remove the bolt, filter cover and filter gasket.

  9. REMOVE LEVEL WARNING SWITCH


    1. A003DC2

      Clamp the fuel filter assembly in a vise between aluminum plates.

      Note

      Be careful not to damage the fuel filter cap.

    2. Using pliers, remove the level warning switch.

      Note

      Be careful not to damage the level warning switch.

    3. Remove the gasket from the level warning switch.

  10. REMOVE FUEL FILTER ELEMENT SUB-ASSEMBLY

    A00E81WE01

    1. Using SST, remove the fuel filter element.

      SST
      09228-64010

  11. INSTALL FUEL FILTER ELEMENT SUB-ASSEMBLY


    1. A00E8LT

      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


    1. Install a new gasket to the level warning switch.

    2. Apply fuel to the gasket of the level warning switch.

    3. Install the level warning switch to the fuel filter and tighten it by hand.

  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. A00E7ZUE01

      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. A00E8IVE01

      Connect the No. 4 fuel hose.

      Tech Tips

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

    5. A00E9YPE01

      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. A00E865E01

      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. A00EAPXE01

      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


    1. A00OUZE

      Install the air cleaner case with the 3 bolts.

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

  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  18. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Connect the air cleaner hose.

    2. A00OVRGE01

      Attach the 4 clamps to install the air cleaner.

    3. Connect the No. 2 ventilation hose.

    4. Connect the mass air flow meter connector.

  19. BLEED AIR FROM FUEL SYSTEM


    1. A010OM8

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A010PR6E03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A010QBAE04

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.


      1. When no DTCs are output, the air bleeding is completed.

      2. If any DTCs are output, proceed to the next step.

    13. Clear the DTCs Click here.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  20. INSPECT FOR FUEL LEAK

    Tech Tips

    Using the intelligent tester to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.


    1. Perform Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Enter the following menus: Powertrain / Engine / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop/Start

        Performs inspection of the high pressure fuel system.


        • Engine Speed: 2050 rpm

        • Fuel Pressure: 172000 kPa

        • Target Common Rail Pressure: 176000 kPa

        • Target Pump SCV Current: 1400 mA

        • MAP: 176 kPa

        • MAF: 39 g/sec.

  21. INSTALL NO. 1 ENGINE COVER


    1. A003DQW

      Attach the 4 clips to install the No. 1 engine cover.