Procedures

Injectors And Delivery Lines

Replacing fuel pressure regulator

Special Tools: 999 5484, 999 5666, 999 5972

Draining the fuel system







- Drain fuel system according to Draining the fuel system.

Preparation







5-door models:
- remove all floor hatches and fold back carpet
- remove cover over fuel pump (FP) unit.

4-door models:
- fold forward right rear seat
- remove cargo compartment carpet
- fold back corner of wheel housing panel at shock absorber mounting
- remove cover over fuel pump (FP) unit.

Removing return line







- Carefully disconnect the quick-release connector on return line from fuel pump (FP) unit.
- The return line is not marked in yellow.

Use tool 999 5666. Slide the outer sleeve of the connector upward. Avoid squeezing the sleeve.

Disconnecting the connectors










- Separate all the connectors on the bracket.
- Ensure that all cables routed through the fuel pump (FP) unit hole run freely. Ensure that the cables can freely follow the fuel tank when it is lowered.

Removing fuel filler pipe







- Remove the circlip securing the rubber seal.
- Release the rubber seal from the bodywork.

Removing delivery line







- Disconnect delivery line from fuel line by engine.
- Remove the fuel line rail and remove the delivery line.
- Remove the delivery line from the holder.

Removing the pressure regulator







- Remove the hose connected to the reference air connector for the pressure regulator.
- Remove the return line from the bracket above the fuel filter.
- Disconnect the delivery line from the fuel filter.

Removing the fuel tank







- Position the mobile jack with fixture 999 5972 under the fuel tank. Check that the lifting platform is flat so that it does not damage the fuel tank.
- Undo the tank retaining straps and lower the tank slightly.

Removing front bracket







- Detach the front holder for the fuel lines.
- Lower the fuel tank further.

Installing new pressure regulator







- Remove the upper fuel line the bracket.
- Remove the old pressure regulator.
- Connect the new pressure regulator the quick-release the connector to the fuel pump (FP) unit and route it forward along the delivery line.
- Install fuel lines and cables in the upper the bracket.

Installing fuel tank







- Raise the tank so that the fuel lines and electrical cables can be installed in the front mounting.
- Install fuel lines and cables in the front bracket.
- Arrange cables running through the fuel pump (FP) unit hole so that they are not trapped when the tank is installed.
- Raise the fuel tank and secure it to the bodywork.

Installing pressure regulator







- Connect delivery pipe the quick-release the connector to fuel filter.
- Install the return line in the bracket above the fuel filter.
- Install fuel lines in holders.
- Connect reference air hose to pressure regulator.
- Locate cable fuel line rail lengthwise.
- Press fuel lines into place on fuel line rail.
- Hold fuel line rail against the floor of the car and tighten. Use new clips and sleeves.
- Connect the delivery line to the fuel line at the engine and install it in the bracket. Close the bracket.

Installing fuel filler pipe







- Install rubber seal at fuel tank filler cap.
- 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 the sealing surfaces (2) of the rubber cover with petroleum jelly. Install cover and circlip (4).
- Connect the connectors to fuel pump (FP), level sensor, ABS sensors and any fuel tank pressure sensor.
- Install panels, covers and carpets.