Removal and Replacement
Fuel tank, replacing
Fuel tank, replacing
Special tools:
981 2270 PUMP TROLLEY 981 2270 Pump Trolley
981 2273 PUMP 981 2273 Pump
981 2282 Tank 981 2282 Tank
998 5972 JACK 998 5972 Jack
999 5533 Holder 999 5533 Holder
999 5485 KEY 999 5485 Key
999 5486 KEY 999 5486 Key
999 5972 FIXTURE 999 5972 Fixture
Safety
First read Safety regulations for handling fuel Safety Regulations For Handling Fuel.
Preparations
Draining the fuel tank
To drain the fuel tank, see Draining the fuel tank AWD and 2WD/ORVR Service and Repair (IE00 (IE01)).
Draining the fuel system
To drain the fuel system, see Draining fuel injection system Draining Fuel Injection System.
Note! Do not drain the fuel tank via the fuel filler pipe as this may damage the check valve.
5-door models:
- Remove all the floor hatches. Fold the carpet out of the way
- Remove the cover over the fuel pump (FP) unit.
4-door models:
- Fold the right rear seat forward
- Remove the cargo compartment carpet
- Fold back the corner of wheel housing panel at the shock absorber mounting
- Remove the cover over the fuel pump (FP) unit.
Disconnect the connectors
- Separate all the connectors on the bracket
- Remove the rubber bracket around the wiring
- Remove the ground lead for the fuel filler pipe from the nut on the cover of the fuel tank level sensor
- Ensure that all cables routed through the hole at the fuel pump (FP) unit are unimpeded. Ensure that the cables can freely follow the fuel tank when it is lowered.
Disconnecting hoses
- Carefully disconnect the quick-release connectors for the delivery and return lines
- Use tool 999 5666 Wrench 999 5666 Wrench. Slide the outer sleeve of the connector upward. Avoid squeezing the sleeve.
Remove the fuel filler pipe
- Remove the fuel tank filler cap
- Remove the snap ring securing the rubber seal
- Release the rubber seal from the bodywork.
Remove the fuel tank
- Disconnect the connector / inlet. Press in the catch and pull.
- Position the mobile jack with fixture 999 5972 FIXTURE 999 5972 Fixture under the fuel tank. Check that the lifting table is level so that the tank will not be damaged
- Undo the tank retaining straps and lower the tank slightly.
Remove front holders and hoses
- Disconnect the hose (1) between the EVAP canister shut-off valve and air cleaner (ACL) from the fuel tank clamp. Cut the tie straps on the fuel filler pipe. Disconnect the hose (2), air cleaner (ACL) and shield from the fuel filler pipe. Put to one side
- Remove the entire mounting from the bracket: Pull it towards the right of the car
- Note the position of the hoses in the clamp. Open the clamp. The hoses must be reinstalled in their original positions.
Disconnect hoses
- Lower the fuel tank slightly
- All hoses are secured on top of tank by a quick-release clip. Use a screwdriver to disconnect the clip at the top
- Lower the tank.
Removing the fuel filler pipe
- Disconnect the hose connectors to the shut-off pipe and the fuel filler pipe
- Remove the two screws on the flange that holds the fuel filler pipe. Pull out the pipe with its rubber seal and check valve.
Transferring the fuel tank pressure sensor
- Remove the screw
- Remove the clamp.
Note! Reuse the clamp.
Removing the clamp:
- Squeeze the clamp using a pipe wrench. Hold in place
- Pry apart using a small screwdriver
- Disconnect the hose
- Remove the cable harness
- Install the pressure sensor on the new fuel tank, route the cabling as before.
Installing the clamp:
- Squeeze the clamp using a pipe wrench until it locks.
Removing the fuel pump (FP)
Remove the nuts securing:
- The level sensor. Use wrench 999 5486 KEY 999 5486 Key
- The fuel pump (FP) unit. Use wrench 999 5485 KEY 999 5485 Key.
- Lift out the fuel pump (FP) unit and level sensor.
Caution! Lift straight up. Do not grip the pipe connections with pliers or other sharp tools. Damage to connections may result in fuel leakage.
- Remove the seals.
Installing the fuel tank
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
When installing a new fuel tank use new nuts. When servicing the fuel tank use the old nuts as the material expands. Failure to do so may result in fuel leakage.
Components to be replaced when installing a new fuel tank:
- The level sensor nut (white)
- The gasket for the level sensor nut
- Fuel pump (FP) nut (black)
- The gasket for the fuel pump (FP) nut
- The gasket for the fuel filler pipe.
Transfer the reinforcement plate from the underside of the old fuel tank to the new fuel tank. Transfer the protective plate from the left-hand side of the old fuel tank to the new fuel tank. Tighten to 10 Nm .
Installing fuel pump (FP) / level sensor
- Lubricate the inside and upper surface of the fuel pump (FP) unit and level sensor seal using petroleum jelly
- Install the seals.
Install:
- The fuel pump (FP) unit
- The level sensor.
Note! Check the seating of the fuel pump (FP) unit and level sensor as illustrated.
- Install the heater connector on the right and the level sensor with its cable on the left, see arrow.
Caution! The engine may stall if the fuel tank unit is installed incorrectly.
Installing nuts
- Tighten the large nut. Tighten to 40 Nm
- Tighten the small nut. Tighten to 30 Nm
- Check that cable is routed from the level sensor as illustrated.
Installing the fuel filler pipe
- Install the rubber gasket on the fuel tank connector
- Lubricate the inside of the seal and the lower end of the filler pipe if necessary
- Check that the check valve is seated correctly with its flap in position on the pipe (shake the tank and listen to ensure that it does not rattle)
- Press the pipe firmly into the seal so that it slides into position.
Install:
- The filler pipe flange
- The screws. Tighten to 10 Nm
- The hose for the shut off pipe.
A new fuel tank has been introduced. See " Service Bulletin 23-0047".
Installing the fuel tank
- Position the fuel tank on the jack
- Use the same fixture and lifting table as for removing it
- Lift the tank slightly.
Installing the fuel lines
- Lubricate the delivery and return connectors lightly using petroleum jelly
- Install the delivery and return lines on the fuel pump (FP) unit. The delivery pipe is marked yellow. The pump has a corresponding color marking
- Install the connectors straight onto the lines. Press down towards the flat surface of the pump. Do not damage the O-rings.
Note! Ensure that the lines are correctly positioned.
- Position all the cables in the clip on top of the fuel tank. Lock the clip.
Installing the fuel tank
- Raise the fuel tank so that the front holder can be installed on the bracket. Position hoses and wiring in the holder. Lock the holder by pressing it until it locks securely onto the bracket
- Ensure that the wiring routed through the hole at the fuel pump (FP) unit will not be trapped when the fuel tank is installed
- Raise the fuel tank. Secure the fuel tank to the bodywork. Tighten to 25 Nm
- Install the EVAP canister shut-off valve hose in the clamp on the fuel tank. Install the hose, air cleaner (ACL) and shield onto the fuel filler pipe. Use 4 tie straps.
- Install the connector / inlet on the EVAP canister. Check that its catch engages.
Installing the rubber cover on the fuel filler pipe
- Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal
- Check that the snap ring (1) is in position
- Lubricate the sealing surfaces (2) of the rubber cover with petroleum jelly
- Install the rubber cover (ensure that it is correctly seated on the bodywork)
- Install the snap ring (4) and drain pipe (3).
- Check that the fuel tank is centered in the holes
- Connect all the connectors.
Warning! Install the ground lead for the fuel filler pipe onto level sensor cover
- Install the rubber bracket around the wiring
- Install panels, covers and carpets.
Note! When filling the tank after replacing it: fill the first 8 liters slowly (maximum 15 l/min). Failure to do so may result in fuel spillage.