Fuel Tank, Replacing

Fuel Tank, Lines And Evaporative System

Fuel tank, replacing

Removal

Draining the tank
If the fuel tank is more than half full, drain the fuel tank.

In the passenger compartment

Remove







- the backrest.







- the insulation panel.
- Remove the covers over the fuel level sensors
- Disconnect the 2 connectors on the left and 2 - 3 on the right-hand side. Let them follow the fuel tank down.

Exhaust pipe, rear section
Raise the car

Remove







- the rear section of the exhaust pipe. Support the front section of the exhaust pipe so as not to put strain on the exhaust manifold.

Heat deflector plate







- Remove the left rear wheel
- Remove the rear plastic nut from the plastic fender liner.
- Drill out the two blind rivets holding the heat deflector plate at the rear sub-frame mounting and the third rivet on the rear bracket for the exhaust system. Use a 5 mm drill bit
- Remove the plastic nuts and the heat deflector plate.

Exposing the fuel tank

Remove







- the plastic pipe with the largest connection to the carbon filter container by pressing towards the container, pressing the two catches and pulling off. Position the pipe forwards towards the fuel tank
- the plastic pipe between the canister purge (CP) valve and the carbon filter container from the clip on the fuel tank
- the ABS wiring from the fuel tank
- the bracket for the fuel filter
- the brake cable from the left rear brake. See Replacing brake cables
- the screws from the heat shield at the front of the fuel tank. Position the brake cables in front of the heat shield
- the hose clamps, fuel filler pipe and the shut-off pipe at the fuel tank.

Tank, lowering







Apply the mobile jack with fixture 999 5972 under the fuel tank.

Remove
- the tank retaining straps and lower the tank slightly
- the hoses from the tank unit.

Check that the lines and wiring are unimpeded during the rest of the lowering.

Draining fuel tank
Drain the fuel from the fuel tank.

Transferring components

Transfer
- the right-hand level sensor and pump.
- the left-hand level sensor.
- the fuel tank pressure sensor.
- the hoses for the fuel filler pipe and breather pipe
- the fuel filler extension in the fuel tank
- the heat shield under the fuel tank
- the clip for the brake cable
- the tank straps.

Installation

Fuel tank







NOTE: To ensure that there is no exhaust leakage.

- Lift up the fuel tank
- Install the hoses on the fuel tank unit. Ensure that no lines or wiring are trapped
- Position the wiring to be routed into the passenger compartment uppermost
- Install the fuel filler pipe and the bleed pipe. Use new screw clips

NOTE: Install the screw clips so that they can be easily tightened.

- Tighten the screws for the tank retaining strap. Tighten to 25 Nm
- Remove the mobile jack.

Install
- the fuel filter with the bracket Tighten to 25 Nm
- The ABS wiring in the clips on the fuel tank
- the brake cables behind the heat shield at the front edge of the fuel tank and in the clips. Screw the heat shield into place
- the brake cable at the left rear brake.
- the plastic pipe between the canister purge (CP) valve and the carbon filter container in the clip on the fuel tank
- the plastic pipe with the largest connection to the carbon filter container. A "click" must be heard.

Heat deflector plate







- Position the heat deflector plate and install the plastic nuts
- Install the pop rivets, one at the bracket for the exhaust system and two on the rear mounting for the sub-frame
- Install the left rear wheel.

The rear section of the exhaust pipe







- Install the exhaust system and its gasket and nuts. Tighten the screws. Tighten to 25 Nm.

The passenger compartment

Install







- The 2 - 3 connectors on the right and the 2 connectors on the left
- the covers over the level sensors. Check that the gasket is correctly positioned
- the insulation panel
- the backrest.