Required Operation

1. Remove the fuel filler cap, then reinstall it. This will release pressure in the fuel tank and prevent fuel spray when the fuel return pipe is removed.





2. Remove the air intake hose by loosening the hose clamps.

!!CAUTION!!
After removing the hose, apply tape to cover the intercooler pipe and hose, to prevent entry of foreign material during this repair.

3. Remove the engine cover.





4. Remove the harness clips to access the fuel return pipe.





5. Remove the two bolts from the engine cover bracket.

REMOVE ENGINE COVER BRACKET (2 BOLTS)





6. Loosen the hose clamps at both ends of the fuel return pipe and pull off the hoses. Then remove the three bolts securing the pipe and remove the pipe from the engine compartment.

!!WARNING!!
Some fuel leakage may occur. Cover the pipe ends and hoses with a cloth.





7. Remove the bolt for the vacuum pipe located in front of the engine. Retain this bolt.





Use this bolt to secure Bracket A (small bracket provided in the repair kit) in the same location. Do not torque the bolt yet (finger-tight only).





8. Remove the bolt for the vacuum pipe located at the LH side of the engine. Install Bracket B (large bracket provided in the repair kit) using the new 8X16 bolt provided in the repair kit.

Tighten the bolt to 23.5 Nm +/- 3.5 Nm (16.5 +/- 2.6 ft/lb.).





CAUTION
Be sure to use the new, longer bolt (size 8X16) provided in the kit for Bracket B (large bracket). Discard the old 8X14 bolt.





9. Torque the bolt securing Bracket A (small bracket) to 10 Nm +/- 2 Nm (7.5 +/- 1.5 ft/lb or 90 +/- 18 in/lb).





10. Install the new fuel return pipe provided in the kit. Secure it with 3 bolts and two nuts tightened to 5.5 Nm +/- 1.5 Nm (4 +/- 1.2 ft/lb or 48 +/- 14 in/lb).

11. Connect the hoses to both ends of the new fuel return pipe. DO NOT APPLY ANY LUBRICANT TO THE HOSES. Reinstall the hose clamps.

CAUTION
Be sure the hoses are fully inserted onto the new fuel return pipe and the hose clamps are securely installed in the correct locations. 18 in/lb).

12. Torque the two bolts from the engine cover bracket to 8 NM +/- 2 Nm (6 +/- 1.5 ft/lb or 72 +/- 18 in/lb).





13. Reinstall the harness clips.

14. Confirm that all attaching hardware in the engine compartment has been securely installed.

15. Remove the tape that was applied in Step 2. Then reinstall the air intake hose. DO NOT APPLY ANY LUBRICANT TO THE HOSE.

CAUTION
Be sure the air intake hose is fully installed and the hose clamps are securely installed in the correct locations.

16. Start the engine and allow to idle for one minute. Confirm there is no fuel leakage at the fuel return pipe and hose connections.

17. Turn off the engine. Reinstall the engine cover.