Evaporative Emissions System: Service and Repair

Fuel Delivery, Return And Evaporation Lines

REMOVAL

WARNING: Place "NO OPEN FLAMES" signs near the working area.

CAUTION: Be careful not to spill fuel.

1. Set the vehicle on a lift.
2. Release the fuel pressure.
3. Open the fuel filler flap lid, and remove the fuel filler cap.
4. Remove the floor mat.
5. Disconnect the fuel delivery pipes and hoses, and then disconnect the fuel return pipes and hoses, evaporation pipes and hoses.






6. Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.
ST 42099AE000 CONNECTOR REMOVER

CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.






7. Disconnect the fuel return hose using the ST.
ST 18371AA000 CONNECTOR REMOVER

CAUTION:
- Be careful not to spill fuel.
- Catch the fuel from hoses using a container or cloth.

1. Attach ST to the fuel return pipe as shown in the figure.






2. Insert the front side of ST into the quick connector.






3. Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.






8. Remove the clip and disconnect the evaporation hose from the fuel pipe.






9. Lift up the vehicle.
10. Remove the fuel tank.
11. Separate the quick connector of fuel line.
1. Clean the pipe and connector, if they are covered with dust.
2. To prevent from damaging or entering foreign matter, wrap the pipes and connectors with plastic bag etc.






3. Hold the connector (A) and push the retainer (B) down.
4. Pull out the connector (A) from the retainer (B).






INSTALLATION

1. Connect the quick connector on fuel line.

CAUTION: Make sure there are no damage or dust on connections. If necessary, clean seal surface of pipe.

NOTE: Use a new retainer.






1. Set the new retainer (B) to connector (A).
2. Push the pipe into the connector completely.






CAUTION:
- Pull the connector to ensure it is connected securely.
- Make sure the two retainer poles are engaged in their mating positions in the connector.
- Be sure to inspect hoses and their connections for any leakage of fuel.






2. Connect the fuel delivery hose and return hose to the pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the amount to be inserted is specified.
Type B: When the amount to be inserted is not specified.

l: 2.5 ±1.5 mm (0.098 ±0.059 in)
L: 22.5 ±2.5 mm (0.886 ±0.098 in)

CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel.






3. Connect the evaporation hose to the pipe with an overlap of 15 to 20 mm (0.59 to 0.79 in).