Fuel Tank: Service and Repair
Special tools: 9812270, 9812273, 9812282, 999 5485, 999 5486, 999 5972
Draining Fuel Tank
- Use draining unit 9812270, 9812273 and 9812282. Insert hose in filler pipe.
NOTE: Insert hose at least 1 meter to get to the fuel. End of hose may have to be cut at an angle to get past all sharp edges.
Preparation
5-door models:
- Remove all floor hatches and fold back carpet.
- Remove the cover over the fuel pump (FP) unit.
4-door models:
- Fold right rear seat forwards.
- Remove luggage compartment mat.
- Fold back corner of wheel arch panel by shock absorber mounting.
- Remove the cover over the fuel pump unit.
Disconnecting Connectors
- Disconnect all connectors on the bracket.
- Remove rubber bracket on cables.
- Ensure that the cables that pass through the fuel pump unit hole are free and can follow the fuel tank when it is lowered.
Disconnecting Hoses
- Carefully disconnect quick-release connectors on delivery and return hoses.
- Use tool 999 5533. Slide outer sleeve of connector upward. Avoid squeezing sleeve.
Removing Fuel Tank
- Remove fuel tank filler cap, rubber cover and circlip.
- Position mobile jack with fixture. 999 5972.
- Use flat lifting table to avoid damage to internal tank components.
- Undo tank retaining straps and lower tank slightly.
Removing Front Mounting
- Remove mounting from bracket by pulling it to the right of the car.
- Lower fuel tank further.
Removing Hoses
- Disconnect EVAP system hose connector
- All hoses are secured in position by quick-release clip on top of tank. Use screwdriver to undo top end of clip.
- Lower tank.
Removing Fuel Filler Pipe/Fuel Tank Pressure Sensor
- Remove fuel tank pressure sensor from fuel tank.
- Disconnect hose connectors to fuel filler pipe.
- Remove the two screws on the flange retaining the fuel filler pipe. Pull out pipe with rubber seal and check valve.
Removing Fuel Pump/Level Sensor
Remove nuts securing:
- Level sensor. Use wrench 999 5486
- Fuel pump unit. Use wrench 999 5485.
- Lift out fuel pump unit and level sensor.
NOTE: Lift unit straight up. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in fuel leakage.
- Remove seal.
Installing Fuel Tank
- When replacing fuel tank use new nuts. When servicing the fuel tank use old nuts as the material expands. Failure to do so may result in fuel leakage.
- Parts to be replaced when replacing a fuel tank:
^ Level sensor nut (white).
^ Level sensor nut seal.
^ Fuel pump nut (black).
^ Fuel pump nut seal.
^ Fuel filler pipe seal.
- Reinstall the reinforcement plate from the bottom of the old fuel tank and the protective plate from the left of the old fuel tank with the new fuel tank. Tightening torque 10 Nm.
Installing Fuel Pump/Level Sensor
- Lubricate the inside and upper surface of the fuel pump unit and level sensor seal with petroleum jelly.
- Install seals.
Install:
- Fuel pump (FP) unit
- Level sensor.
NOTE: Check the seating of the fuel pump unit and level sensor using illustration.
- Install heater connector on the right and level sensor with cable on the left, see arrow.
CAUTION: Engine may stall it the fuel pump unit is installed incorrectly.
Installing Nuts
- Tighten large nut to 40 Nm.
- Tighten small nut to 30 Nm.
- Check level transmitter wiring as illustrated.
Installing Fuel Filler Pipe
- Install rubber seal, P/N 6842188-2 to fuel tank collar.
- Oil inside of seal and, if necessary, lower end of filler pipe.
- Check that check valve is positioned correctly with flap in position against pipe (shake tank and listen to ensure it does not rattle).
- Press pipe firmly into seal so that it slides into position.
Install:
- Filler pipe flange.
- Screws. Tighten to 10 Nm.
Installing Tank Pressure Sensor/hoses
- Install tank pressure sensor.
- Reconnect hoses to fuel tank.
- See illustration for correct location.
- Tighten clips to 3.5 Nm.
- Turn clips to avoid rubbing against floor.
NOTE: Check nipple on top of tank.
Installing Fuel Tank
- Put fuel tank on jack.
- Use same fixture and lifting table as when removing tank.
- Lift tank slightly.
Installing Fuel Lines
- Install EVAP system hose.
- Lubricate delivery and return connectors lightly with petroleum jelly.
- Reconnect delivery and return lines to pump unit. Delivery hose is marked with yellow tape, corresponding to color coding on pump flange.
- Reconnect connectors straight, press down to flat surface of pump. Ensure that 0-rings are not damaged.
NOTE: Ensure that cables are correctly positioned.
- Install all cables on the clip on top of the tank.
Installing Fuel Tank
- Raise the tank so that front mounting can be installed to the bracket.
- Install the front mounting to the bracket
- Ensure that cabling routed through the fuel pump unit hole will not be trapped when the fuel tank is installed.
- Raise the fuel tank and fix it to the bodywork.
Installing Fuel Filler Pipe Rubber Cover
- Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.
- Check that circlip (1) is in position.
- Lubricate sealing surface of rubber cover (2).
- Install rubber cover (ensure that it is correctly positioned in relation to bodywork).
- Install circlip (4) and drain pipe (3).
- Connect connectors to fuel pump, level sensor, fuel tank pressure sensor and ABS sensors.
- Install rubber bracket around wiring.
- Install panels, covers and carpets.