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. A388566

      Disconnect the level warning switch connector.

    2. A388567

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

    3. A388568

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

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

    1. A354356

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

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

    1. A401846

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

    2. A401852C01

      *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. A388570

      Disconnect the fuel filter assembly connector.

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

    5. A388571

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

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

    1. A354337C01

      *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. A354355C01

      *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. A354357

      Disconnect the fuel filter assembly connector.

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

    5. A316286

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

  8. DRAIN FUEL (w/ Fuel Heater Relay)

    1. A403875

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

    2. A388577

      Remove the O-ring from the drain cock.

    3. Tighten the drain cock.

      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. A388573N01

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

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

      09228-64010

      Note:

      Be careful not to damage the fuel filter cap.

    3. Remove the fuel filter cap from the vice.

    4. A388578

      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. A388573N01

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

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

      09228-64010

    6. A388610

      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. A388609C02

      *a

      Protrusion

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

    2. A388574

      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.

      12.5 N*m

      127 kgf*cm

      111 in.*lbf

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

      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.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

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

      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.

      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.

      17.5 N*m

      178 kgf*cm

      13 ft.*lbf

  16. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  17. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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

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  19. INSPECT FOR FUEL LEAK

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