ICOM FUEL FILL HOSE ND FILTER INSTLLTION INSTRUCTIONS P5X4-9245- Revision: - Dated /8/5 Replaces: None
TBLE OF CONTENTS PROCESS # PROCESS NME P5X4-9245-000 INSTLL FUEL FILL HOSE & FILTER (EXTERNL MOUNTED TNKS ONLY) P5X4-9245-0020 INSTLL REMOTE FUEL FILL HOSE (INTERNL MOUNTED TNKS ONLY) P5X4-9245-0030 INSTLL FUEL FILL FILTER (INTERNL MOUNTED FILTER ONLY)
CRITICL PROCESS OPERTION 0) OBTIN FUEL FILL FILTER SSY () ND REMOTE FUEL FILL HOSE KIT (B) 0 20) DETERMINE LOCTION FOR THE INLINE FUEL FILL FILTER SSY ON THE VEHICLE 30) DETERMINE LOCTION FOR THE REMOTE FUEL FILL VLVE ON VEHICLE B 40) REMOVE THE CONTENTS FROM THE REMOTE FUEL FILL HOSE KIT; DETERMINE THE LENGTH OF HOSE NEEDED TO GO FROM THE FUEL TNK TO THE INLINE FUEL FILTER ND FROM THE OPPOSITE END OF THE INLINE FUEL FILTER TO THE REMOTE FUEL FILL VLVE 50) CUT ND SSEMBLE THE FILL HOSES NEEDED PER THE ICOM WORK INSTRUCTION FOR SSEMBLY OF THE HOSES (PX-9203-C) 60 60) LOCTE THE FILL VLVE MOUNTED ON THE FUEL TNK 70) USING -/6" WRENCH TO HOLD THE FILL VLVE IN PLCE, ROTTE THE 90 DEGREE FITTING (CLOCKWISE DIRECTION ONLY) USING 3/4" OPEN END WRENCH INTO THE DESIRED POSITION NOTE - MKE SURE THE MRKING STMPED ON THE FCE OF THE FILL VLVE REMINS T THE 2 O'CLOCK POSITION WHEN POSITIONING THE 90 DEGREE FITTING OR THE FILL VLVE WILL NOT FUNCTION PROPERLY 80) HNDSTRT HOSE FITTING ONTO FILL VLVE FITTING; THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 70 80 ITEM PRT NUMBER QTY DESCRIPTION TOOLS 709000 FUEL FILL FILTER SSY WRENCH 25Nm +/- 2.5 B 3702-B HOSE KIT - REMOTE FUEL FILL 9mm OPEN END WRENCH 22mm CROWFOOT PROCESS NME INSTLL FUEL FILL HOSE & FILTER (EXTERNL TNKS ONLY) P5X4-9245-000 PGE OF 4
CRITICL PROCESS OPERTION 90 90) OBTIN 0 FOOT SECTION OF CORRUGTE (C ); DETERMINE THE LENGTH OF CORRUGTE NEEDED TO COVER THE HOSE JUST PIOUSLY INSTLLED; CUT & INSTLL THE CORRUGTE ONTO THE HOSE 00 2 00) OBTIN FILL HOSE FILTER (B); USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, BOTH END FITTINGS WITH 22mm OPEN END CROWFOOT ND WRENCH TO 45 Nm +/- 4.5 0) POSITION FUEL FILTER WITH RROW ON FILTER HOUSING POINTING TOWRD THE FUEL TNK 0 20) HNDSTRT FITTING ON HOSE COMING FROM THE FUEL TNK ONTO RROW END OF FILTER HOUSING 30) USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 20 30 ITEM PRT NUMBER QTY DESCRIPTION TOOLS C 350024 CORRUGTE - 0' WRENCH 25Nm +/- 2.5 9mm OPEN END WRENCH 22mm CROWFOOT 2 45Nm +/- 4.5 24mm OPEN END WRENCH PROCESS NME INSTLL FUEL FILL HOSE & FILTER (EXTERNL TNKS ONLY) P5X4-9245-000 PGE 2 OF 4
CRITICL PROCESS OPERTION 40) OBTIN THE SECOND SSEMBLED FILL HOSE FROM STEP 50 50) HNDSTRT HOSE FITTING ONTO FILTER 50 60 60) USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 70 70) OBTIN THE LEFT OVER 0 FOOT SECTION OF CORRUGTE (C ); DETERMINE THE LENGTH OF CORRUGTE NEEDED TO COVER THE HOSE JUST PIOUSLY INSTLLED; CUT & INSTLL THE CORRUGTE ONTO THE HOSE 80 D 80) SECURE FILTER HOUSING TO DESIRED LOCTION ON VEHICLE WITH SUPPLIED CLMP & SELF TPPING SCREW DO NOT SCREW DIRECTLY INTO FLOOR, ONLY SCREW INTO SUPPORTS / BRCES FOR FLOOR WITH SUPPLIED FUEL FILTER MOUNTING CLMP(S) ITEM PRT NUMBER QTY DESCRIPTION TOOLS 7095000 FUEL FILL FILTER SSY WRENCH 45 Nm +/- 4.5 C 350024 CORRUGTE - 0' 24mm OPEN END WRENCH D 330003 2 FUEL FILTER CLMP 22mm CROWFOOT 25 Nm +/- 2.5 E 382 2 SELF TP SCREW 2 PROCESS NME INSTLL FUEL FILL HOSE & FILTER (EXTERNL TNKS ONLY) P5X4-9245-000 PGE 3 OF 4
CRITICL PROCESS OPERTION 90) HNDSTRT FILL HOSE FITTING ONTO FILL VLVE NOZZLE 200) USING WRENCH TO HOLD THE FILL VLVE, FILL HOSE FITTING WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 90 200 ITEM PRT NUMBER QTY DESCRIPTION TOOLS WRENCH 25Nm +/- 2.5 22mm CROWFOOT PROCESS NME INSTLL FUEL FILL HOSE & FILTER (EXTERNL TNKS ONLY) P5X4-9245-000 PGE 4 OF 4
CRITICL PROCESS OPERTION 0 E 0) OBTIN THE REMOTE FILL HOSE KIT (E ) 20 20) ROUTE THE CRIMPED FITTING END OF THE HOSE THROUGH THE HOLE IN THE VEHICLE PNEL ND INTO THE OPENING OF THE LOWER VPOR SEL COVER 30) INSTLL & HNDSTRT HOSE FITTING ONTO FILL VLVE ON TNK; USING WRENCH WITH 22mm OPEN END CROWFOOT, THE HOSE FITTING TO 25 Nm +/- 2.5 30 ITEM PRT NUMBER QTY DESCRIPTION TOOLS WRENCH 25 Nm +/- 2.5 22mm CROWFOOT PROCESS NME INSTLL REMOTE FUEL FILL HOSE (INTERNL MOUNTED TNKS ONLY) P5X4-9245-0020 PGE OF 3
CRITICL PROCESS OPERTION 40 40) OBTIN THE UPPER VPOR SEL COVER IDENTIFIED IN THE PHOTO C 50) LIGN & SET THE CENTER HOLE IN THE UPPER COVER ONTO THE UPPER THREDED STUD TTCHED TO THE FUEL TNK; LIGN & SET THE UPPER COVER ONTO THE O-RING ON THE LOWER COVER 60) OBTIN () VPOR SEL COVER NUT (D) 70) INSTLL & HNDTIGHTEN NUT (D) ONTO THREDED STUD S SHOWN 50 80) VERIFY PROPER SEL OF UPPER & LOWER COVERS ND LOWER COVER TO TNK THREDED STUD 70 O-RING 60 D 80 ITEM PRT NUMBER QTY DESCRIPTION TOOLS C PI WITH TNK VPOR SEL COVER SSY PROCESS NME INSTLL REMOTE FUEL FILL HOSE (INTERNL MOUNTED TNKS ONLY) P5X4-9245-0020 PGE 2 OF 3
CRITICL PROCESS OPERTION 90) PPLY UNIFORM BED OF SILICONE ROUND THE PSSENGER SIDE VPOR COVER NOZZLE TO THE VEHICLE PNEL S SHOWN 90 ITEM PRT NUMBER QTY DESCRIPTION TOOLS CLER SILICONE PROCESS NME INSTLL REMOTE FUEL FILL HOSE (INTERNL MOUNTED TNKS ONLY) P5X4-9245-0020 PGE 3 OF 3
CRITICL PROCESS OPERTION 0) OBTIN FILL HOSE FILTER (); USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, BOTH END FITTINGS WITH 22mm OPEN END CROWFOOT ND WRENCH TO 45 Nm +/- 4.5 20) INSERT FUEL FILL HOSE COMING FROM THE TNK INTO THE VPOR SEL FITTING; POSITION THE FUEL FILTER WITH THE RROW ON THE FILTER POINTING TOWRD THE FILL HOSE S SHOWN 0 30) HNDSTRT FILL HOSE FITTING ONTO FILTER 30 40 2 40) USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 20 50) OBTIN REMOTE FILL HOSE KIT (B) 60) DETERMINE THE LENGTH OF HOSE NEEDED TO GO FROM THE OPPOSITE END OF THE INLINE FUEL FILTER TO THE REMOTE FUEL FILL VLVE 70) CUT ND SSEMBLE THE FILL HOSE NEEDED PER THE PROVIDED WORK INSTRUCTION FOR SSEMBLY OF THE HOSES (PX-9203-C) 80) HNDSTRT FILL HOSE FITTING ONTO FILTER 90) USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 60 70 80 90 2 ITEM PRT NUMBER QTY DESCRIPTION TOOLS 7095000 FUEL FILTER SSY WRENCH 45Nm +/- 4.5 B 3702-B REMOTE FILL HOSE KIT 24mm OPEN END WRENCH 22mm CROWFOOT 2 25Nm +/- 2.5 PROCESS NME INSTLL FUEL FILL FILTER (INTERNL MOUNTED ONLY) P5X4-9245-0030 PGE OF 3
CRITICL PROCESS OPERTION VPOR SEL HOSE (KNFLEX HOSE) MUST BE INSTLLED BETWEEN THE VPOR SEL FITTING ND THE FILL HOUSING TO CONCEL THE FUEL FILTER ND HOSE FITTINGS 00) OBTIN KNFLEX HOSE (E) ND (2) 3" HOSE CLMPS (F) 00 0) INSTLL () 3" HOSE CLMP ONTO ONE END OF THE KNFLEX HOSE; INSTLL KNFLEX HOSE ONTO FILL HOSE ND FUEL FILL FILTER S SHOWN 0 20) LIGN ND SET HOSE ONTO UPPER VPOR SEL FITTING; INSTLL ND POSITION HOSE CLMP OVER FITTING; FULLY TIGHTEN HOSE CLMP TO SECURE HOSE TO FITTING 20 ITEM PRT NUMBER QTY DESCRIPTION TOOLS PROCESS NME INSTLL FUEL FILL FILTER (INTERNL MOUNTED ONLY) P5X4-9245-0030 PGE 2 OF 3
CRITICL PROCESS OPERTION 30) HNDSTRT FILL HOSE FITTING ONTO FILL VLVE NOZZLE 40) USING WRENCH TO HOLD THE FILL VLVE, FILL HOSE FITTING WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 30 40 50) DETERMINE LENGTH OF HOSE NEEDED TO GO FROM THE VPOR SEL FITTING TO THE VPOR SEL ON THE BCKSIDE OF THE FILL HOUSING ND CUT S REQUIRED 60) INSTLL HOSE CLMP ONTO HOSE; LIGN ND SET HOSE ONTO FUEL FILL HOUSING; INSTLL ND POSITION HOSE CLMP OVER FILTER HOUSING; FULLY TIGHTEN HOSE CLMP TO SECURE HOSE TO FILL HOUSING 50 60 ITEM PRT NUMBER QTY DESCRIPTION TOOLS E 30000 KNFLEX HOSE - 3" x 5' (IF NEEDED) WRENCH 25Nm +/- 2.5 F 33000 2 3" HOSE CLMP 22mm CROWFOOT PROCESS NME INSTLL FUEL FILL FILTER (INTERNL MOUNTED ONLY) P5X4-9245-0030 PGE 3 OF 3