Fuel Tank, Replacement
Universal tools:
981 2270, 2273, 2282;
Special tools:
999 5465, 5485, 5486, 5972
B1
Disconnect battery
B2
Drain fuel tank
Drain fuel tank using drainage unit using tools 2270, 2273 and 2282. Insert hose in filler pipe.
Note:
Hose must he inserted at least 100 cm (39 in.) to ensure immersion in fuel. End of hose may have to be cut at an angle to get past all sharp edges.
B3
Tilt right-hand rear seat forward
B4
Remove:
- luggage compartment mat
- right-hand wheel housing panel
- covers over level transmitter and fuel pump unit nuts
B5
Disconnect fuel pump and level transmitter connectors
B6
Check color coded markings on hoses and pump
Note:
Delivery hose is marked with yellow tape, corresponding to color code on pump.
B7
Carefully undo quick-release couplings on delivery and return hoses using tool 546S. Slide sleeve of outer coupling upwards without squeezing sleeve
B8
Remove circlip securing filler housing
B9
Remove filler cap and filler housing
B10
Position mobile jack and lifting fixture 5972 under tank
Use flat lifting table to avoid damage to tank internals
B11
Undo tank retaining straps and lower tank slightly
B12
Undo EVAP system connections
A snap-action clip securing all hoses in position is located on top of tank. Use screwdriver to undo clip at top.
B13
Lower tank
B14
Remove/disconnect:
- hose connections (two) at tank
- screws (two) securing filler pipe clamp. Withdraw pipe, complete with rubber seal and non-return (flap) valve.
B15
Remove nuts securing:
- level transmitter, using tool 5486
- pump unit, using tool 5485.
B16
Remove pump unit and level transmitter
Note:
Lift units straight upwards. Do not grip pipe connections with pliers or other sharp tool is damage to connections may result in fuel leakage.
Remove seal.
Installation
When installing a new tank, the following components must be replaced since the material swells. Failure to do so may result in fuel leakage.
Level transmitter nut (white), p/n 3531425-1 Level transmitter nut seal, p/n 3531426-9 Fuel pump unit nut (black), p/n 3501322-6 Fuel pump unit nut seal, p/n 3501323-4 Filler pipe seal, p/n 6842188-2
B17
Remove guard plates (two) from original tank and attach to new tank
Do not forget self-adhesive tape on left-hand side of rear plate
B18
Install new rubber seals on fuel pump unit and level transmitter
Grease top and inside of seals with petroleum jelly.
B19
Install pump unit and level transmitter
Note:
Ensure that pump unit and level transmitter are positioned (as shown)
Ensure that level transmitter lead faces left of car.
B20
Tighten nuts as follows:
Large nut: 40 N-m (30 ft.lb)
Small nut: 30 N-m (22 ft.lb)
B21
Check level transmitter wiring (as shown)
B22
Install tank filler pipe
One of two procedures may be used:
Method 1:
Fit rubber seal, p/n 6842188-2 to connection branch on tank. Oil inside of seal and, if necessary, lower end of filler pipe. Check that non-return valve is positioned correctly with flip in position on pipe. Press pipe firmly into seal so that it slides into position.
B23
Install:
- filler pipe clamp
- screws. Tighten to 10 N-m (7.5 ft.lb)
Method 2:
Fit seal on filler pipe. Check that seal is not bent back when filler pipe is inserted in branch on tank. If this occurs, straighten seal carefully. Do not use tools with sharp edges.
B24
Install:
- filler pipe clamp
- screws. Tighten to 10 N-m (7.5 ft.lb)
B25
Reconnect fuel hoses to tank
See illustration for correct location.
Tighten clips to 3.5 N-m (3 ft.lb).
Position clips so as to avoid abrasion against floor.
Note:
Check connection on top of tank.
B26
Place tank and retaining straps on jack
Use same fixture and lifting table as when removing tank.
B27
Lift tank into position and tighten rear strap
B28
Push tank forward as far as possible. Center tank (as illustrated) so as to ensure that level transmitter nut (white) is clear of hole.
B29
Tighten screws securing front strap
B30
Press hose retaining clip onto strap
B31
Install filler housing around top of filler pipe
Check that inner seal (1) is correctly seated. Oil sealing surface of filler housing (2) and install housing. Install drain tube (3), ensuring that tube is on inside of seal (1), otherwise water (or gasoline) may enter luggage compartment. Install circlip (4).
B32
Reconnect wiring
B33
Install:
- covers over fuel pump unit and level transmitter nuts
- right-hand wheel housing panel
- luggage compartment mat
B34
Raise right-hand rear seat
B35
Fill tank with gasoline
B36
Reconnect battery
B37
Re-enter radio codes
WARRANTY STATEMENT:
Claims may be submitted under the Emission Warranty using:
Oper. No. Labor Description Time Allowance
234043 Fuel tank, drain and fill 0.2 hr
234102 Fuel tank, replace 1.6