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FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTIONFL
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FUEL SYSTEM
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL FILTER .............................................................. 4
Components ............................................................. 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSTALLATION ..................................................... 5
INSPECTION AFTER INSTALLATION ................. 5
Air Bleeding .............................................................. 5
Draining Water from Fuel Filter ................................ 6
FUEL COOLER .......................................................... 7
Components (4WD Models Only) ............................ 7
Removal and Installation (4WD Models Only) ......... 7
REMOVAL ............................................................. 7
INSTALLATION ..................................................... 8
INSPECTION AFTER INSTALLATION ................. 8FUEL TANK ................................................................ 9
Components ............................................................. 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ................................................... 12
INSPECTION AFTER INSTALLATION ................ 13
FUEL LEVEL SENSOR UNIT ................................... 14
Components ........................................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSPECTION AFTER REMOVAL ....................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ................ 15
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
Standard and Limit .................................................. 16
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FL-2
PREPARATION
PREPARATION
PFP:00002
Commercial Service ToolsEBS01E70
Tool nameDescription
Fuel filter wrench Removing fuel filter
Fuel tank lock ring wrench Removing and installing fuel tank lock ring
PBIC0519E
ZZA0122D
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FUEL SYSTEM
FL-3
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS01E71
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsEBS01E72
WARNING:
When replacing fuel line parts, be sure to observe the following.
lPut a “CAUTION: INFLAMMABLE” sign in workshop.
lBe sure to work in a well-ventilated area and furnish workshop with a CO2fire extinguisher.
lDo not smoke while servicing fuel system. Keep open flames and spark away from work area.
CAUTION:
lUse diesel fuel required by the regulations for cetane number. Refer toGI-6, "DIESEL ENGINE".
lBefore removing fuel line parts, perform the following procedures:
–Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
–Disconnect the battery cable from the negative terminal.
lAlways replace O-ring and clamps with new ones.
lDo not kink or twist tubes when they are being installed.
lDo not tighten hose clamps excessively to avoid damaging hoses.
lAfter connecting fuel tube quick connectors, make sure
quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.
lAfter installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–Start the engine and rev it up and check for fuel leaks at
connections.
SMA803A
SBIA0504E
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FL-4
FUEL FILTER
FUEL FILTER
PFP:16400
ComponentsEBS01F6M
lRefer toGI-10, "Components"for symbol marks in the figure.
Removal and InstallationEBS01E73
REMOVAL
1. Disconnect fuel hoses at fuel filter.
CAUTION:
Plug the pipe to prevent fuel from draining.
2. Loosen mounting nuts (2) and remove fuel filter (1).
CAUTION:
Do not splash fuel during removal. If fuel is splashed,
immediately wipe it off.
1. Fuel filter bracket 2. Fuel filter 3. O–ring
4. Drain plug
A. Refer toFL-5
.
PBIC3369E
1 : Fuel filter
2 : Fuel hose (feed)
3 : Fuel hose (return)
PBIC3370E
: Vehicle front
PBIC3337E
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FUEL FILTER
FL-5
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3. Using band-type fuel filter wrench (A) (commercial service tool),
remove fuel filter (1).
4. Turn fuel filter (1) upside down to drain fuel.
5. Remove drain plug (2) from fuel filter.
INSTALLATION
Note the following, and install in the reverse order of removal.
lReplace O-ring on drain plug with new one.
lScrew the fuel filter by hand until packing contacts sealing surface of fuel filter bracket. Then tighten it by
turning approximately 2/3 turn.
lInstall fuel filter (1), and tighten mounting nuts (2) to the speci-
fied torque.
lAfter installation, bleed air from fuel line. Refer toFL-5, "Air Bleeding".
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart the engine and rev it up and make sure there is no fuel leakage at connections.
Air BleedingEBS01E74
After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as
follows:
lMove priming pump (1) up and down to bleed air from fuel path.
When air is bled, pumping of priming pump becomes heavy stop
operation at that time.
lCrank engine until it starts. Do not crank engine for more than 30 seconds.
lIf engine does not start, stop cranking and repeat step 1 above.
lIf engine does not operate smoothly after it has started, race it two or three times.
PBIC3371E
Fuel filter (reference value)
: 13.5 N·m (1.4 kg-m, 10 ft-lb)
: Vehicle front
Fuel filter mounting nuts
: 13.5 N·m (1.4 kg-m, 10 ft-lb)
PBIC3337E
PBIC3372E
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FL-6
FUEL FILTER
lIf air cannot be bled easily (pumping of priming pump does not become heavy), disconnect feed-side of
hose between fuel filter and electronically controlled fuel pump. After that, operate priming pump and con-
firm that fuel comes out.
CAUTION:
Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine
mounting insulator.
Draining Water from Fuel FilterEBS01E75
1. Prepare a tray (A) under the drain plug (1).
2. Loosen drain plug (1), and operate priming pump (2) to drain
water from fuel filter.
CAUTION:
lWater in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
lDrained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
3. Replace O-ring on drain plug with new one.
4. After draining, close drain plug to specified torque.
CAUTION:
If drain plug is tightened excessively, it may be damaged and fuel will leak.
5. Bleed air in fuel piping. Refer toFL-5, "
Air Bleeding".
6. Start engine and make sure there is no fuel leakage.Drain plug
: 1.3 N·m (0.13 kg-m, 12 in-lb)
PBIC3373E
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FUEL COOLER
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FUEL COOLERPFP:17511
Components (4WD Models Only)EBS01FEY
Removal and Installation (4WD Models Only)EBS01FEZ
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer toFL-3, "
General Precau-
tions".
1. Remove protector (fuel tube).
2. Remove protector (fuel cooler) mounting bolts (3 pieces) then disconnect fuel tubes from fuel cooler
assembly.
CAUTION:
lPlug fuel tubes and fuel cooler assembly to prevent fuel from draining.
lDo not splash fuel during removal. If fuel is splashed, immediately wipe it off.
3. Remove fuel cooler assembly from protector (fuel cooler)
CAUTION:
lDo not bend fuel tubes during removal.
lAvoid impacts such as falling when handling components.
1. Fuel tube (return) (to fuel tank) 2. Fuel tube (return) (to engine) 3. Bracket
4. Protector (fuel cooler) 5. Protector (fuel tube) 6. Fuel cooler assembly
7. Bracket
PBIC4059E
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FL-8
FUEL COOLER
INSTALLATION
Note the following, and install in the reverse order of removal.
lInsert hose to the length below when there is no spool on the fuel tube and surely clamp fuel hoses.
lBe sure hose clamp is not positioned on swelled area of fuel tube.
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
lStart engine and rev it up and make sure there is no fuel leakage at connections.Fuel hose : 25 mm (0.98 in)