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.
1. Disconnect the quick connector on the fuel delivery line and return line by pushing the ST in the direction of the arrow.

ST 42099AE000 QUICK CONNECTOR RELEASE

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

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






6. Remove the canister.
7. Remove the fuel tank.
8. Remove the fuel pipe assembly.
9. Disconnect the quick connector, then disconnect the fuel delivery tube, fuel return tube and jet pump tube.
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

Install in the reverse order of removal while being careful of the following.

1. CONNECTING THE FUEL LINE QUICK CONNECTOR

CAUTION: Make sure there is no damage or dust on the 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 pawls are engaged in their mating positions in the connector.
- Be sure to inspect hoses and their connections for any leakage of fuel.






2. CONNECT FUEL DELIVERY HOSE AND FUEL RETURN HOSE
Connect the fuel delivery hose and fuel 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.

L1: 2.5 ± 1.5 mm (0.098 ± 0.059 in)
L2: 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. CONNECTING THE EVAPORATION HOSE

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