Evaporative Emissions System: Service and Repair

Fuel Delivery, Return and Evaporation Lines

REMOVAL
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. In the engine compartment, disconnect the fuel delivery hoses and evaporation hose.
1. Disconnect the quick connector of fuel delivery line and return line by pushing the ST in the direction of arrow.
ST 42099AE000 CONNECTOR REMOVER
2. Remove the clip and disconnect the evaporation hose from pipe.

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

7. Lift-up the vehicle.
8. Remove the fuel tank.
9. Separate the quick connector on 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 retainer (B) down.
4. Pull out the connector (A) from retainer (B).

CAUTION: Always use a new retainer except in use of engine compartment.

INSTALLATION
1. Connect the quick connector on fuel line.

CAUTION:
- Always use a new retainer except in use of engine compartment.
- Make sure that the connected portion is not damaged or dust-covered. If necessary, clean the seal surface of pipe.




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.
- Ensure the two retainer pawls are engaged in their mating positions in the connector.
- Be sure to inspect the hoses and their connections for fuel leakage.




2. Connect the fuel delivery 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.




3. Connect the return hose and evaporation hose to the pipe by approx. 15 mm (0.59 in) from hose end.

Fuel return hose: L = 22.5 ± 2.5 mm (0.886 ± 0.098 in)
Fuel evaporation hose: L = 17.5 ± 2.5 mm (0.689 ± 0.098 in)

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