Service

SERVICE:

1. Removing the protective plate

Remove the protective plate on the left-hand side of the fuel tank.

2. NOTE!
On some models there is a rear protective plate on the fuel tank, if so, remove the bolt in the top right-hand corner as well and fold out the protective plate slightly.

3. Inspecting the mounting

Important!
The fuel tank must be dry from all moisture caused by rain or snow prior to inspecting.

Check the area around the mountings for leaking fuel or cracks. (See picture in step 4)

If the car is equipped with a rear protective plate then check this mounting too.

NOTE!
If fuel tank has cracks or leakage around the attaching lugs then the tank must be replaced. Refer to page 5 shown.

After replacing the tank or if it is considered OK then the protective plate(s) must be refitted with rubber dampers see step 5.

4. Inspecting the mounting

Check the area around the mountings for leaking fuel and/or cracks.

5. Installing the rubber dampers

Install the rubber dampers to the lugs on the tank with the hexagon part of the damper facing the tank.

Tighten the rubber damper so that the hexagon just contacts with the lug surface, then angle tighten an additional 45° (1/8 of a turn).

6. Adjusting the protective plate

Cut off the shaded area as marked in the illustration.

A = 173 mm
B = 135 mm

7. Installing the protective plate

Install the protective plate, tighten the nuts to 10 Nm.

8. Installing the rubber damper to the rear protective plate

NOTE!
Only applies to cars with a rear protective plate for the tank.

Install the rubber damper in the same way as in the previous steps.

Replacing the fuel tank (when necessary)

9. Fuel tank, draining

NOTE!
As the illustrations in this service information are used for different model years and or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparation

Disconnect the battery negative terminal.

See Note when disconnecting/connecting the battery lead.

Note!
Follow all Safety regulations for handling fuel.

Draining fuel tank

NOTE!
Always ensure that there is a ground connection between the fuel intake and the fuel filler pipe.

10. Removing panels

5-door cars:

- Fold up the front floor hatch and fold back carpet.

4-door cars:

- Fold forward right rear seat

Remove:

- cargo compartment carpet

- right wheel arch panel. Fold back the corner of panel on variants with soft panels

- covers over nuts to fuel pump (FP) and level sensor.

NOTE!
If carrying out work on fuel level sensor in a 5-door model, fold the rear seat forward, remove the front floor hatch screws (x 4) and pull hatch backward.

11. Disconnecting hoses

Separate connectors for fuel pump (FP) and level sensor

Check color markings on hoses and pump.

Note!
The delivery pipe is marked with yellow tape. The pump has a corresponding color marking.

Carefully disconnect quick-release connectors on delivery and return hoses. Use tool 999 5533. Slide outer sleeve of connector upward. Avoid squeezing sleeve.

12. Removing fuel tank

Remove:

- spring clip that tensions the rubber seal

- fuel cap and rubber seal.

13. 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.

14. Removing hoses

Disconnect EVAP system hose connector. All hoses are secured in position by quick-release clip on top of tank. Use a screwdriver to release the upper end of the clip.

Lower tank.

15. Remove:

- the two fuel tank hose connectors

- the two screws on the flange retaining the fuel filler pipe. Pull out pipe with rubber seal and check valve.

16. Removing fuel pump (FP)

Remove nut securing level sensor. Use wrench 999 5486.

Remove nut securing fuel pump. Use wrench 999 5485.

17. Lift out:

- fuel pump (FP) unit and level sensor.

Caution!
Lift unit straight up. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in fuel leakage.

18. Installing fuel tank

NOTE!
This step is only information. Follow the method from step 19.

When installing a new fuel tank the following components must be replaced with new parts because the material swells. Failure to do so may result in fuel leakage.

- Level sensor nut (white) (9142607)

- Level sensor nut seal (447142)

- Fuel pump (FP) nut (black) (3501322)

- Fuel pump (FP) nut seal (9447141)

- Fuel filler pipe seal (6842188)

Transfer and install the two covers from the old fuel tank to the new one.

NOTE!
On M/Y 1994, replace the side protective plate PN 9470378.

NOTE!
The protective plate must be adjusted before installing see step 22.

19. Modifying pipe from rollover valve

Cut the pipe on the new tank approx 25 mm past the bend. See the illustration.

20. Installing the rubber dampers

Install the protective plate, tighten the nuts to 10 Nm.

22. Adjusting the protective plate

Cut off the shaded area marked in the Illustration.

A = 173 mm

B = 135 mm

23. Installing the protective plate

Install the protective plate, tighten the nuts to 10 Nm.

24. Installing fuel pump (FP)

Install:

- rubber seal on fuel pump (FP) unit. Lubricate the inside and top of the seal with petroleum jelly.

- fuel pump (FP) unit

NOTE!
Check the alignment of the fuel pump (FP) unit, see illustration.

25. Install fuel level sensor

Install a new level senor on M/Y 1994: emission code 0, 1, 2, 5, 6

Install:

- rubber seal on level sensor

- level sensor.

26. NOTE!
Check the alignment of the level sensor using illustration.

Install the nut finger tight. Check that the position of the level sensor does not change.

27. Installing nuts

Tighten:

- large nut to 40 Nm

- small nut to 30 Nm.

Check level transmitter wiring as illustrated.

28. Installing hoses

Reconnect hoses to fuel tank.

See illustration for correct location.

Tighten hose clamps to 3.5 Nm.

Turn spring clamps so that they do not rub against the body or the tank.

Install rubber seal, P/N 6842188-2 on fuel tank collar.

Lubricate inside of gasket and, if necessary, lower end of filler pipe.

Important:
Ensure that the check valve (C) on the end of the filler neck is in the correct position with its locking tab on the filler pipe.

29. Installing fuel filler pipe on tank 8631059

Install:

- filler pipe flange.

- screws. Tighten to 10 Nm.

- hose (1), with new clamp to the fitting on the tank.

- cut the new hose (2), P/N 969106 to a length of 450 mm.

- new hose (2) with new clamps.

30. Installing fuel filler pipe on tank 8676687

Install:

- filler pipe flange

- screws. Tighten to 10 Nm

- the fuel tank pressure sensor from the old tank

- three joined hoses (1), P/N 9480050, to the fittings. Secure the hoses clamps. The narrower hose is for fuel tank pressure sensor

- hose (2), with new clamp to the fitting on the tank.

31. Installing fuel tank

Installing protective plates on tank install new mounting straps (1) PN 9454593 and 9463196).

32. Installing fuel tank

Rest tank and tank band on jack.

Use same fixture and lifting table as when removing tank.

Raise tank and tighten tank band at rear.

33. Installing fuel tank

Push tank forward as far as possible. Center tank (see illustration) so that the level sensor nut (white) does not contact the edge of the opening.

Tighten front tank band bolt.

Press the clip with the fuel hoses into place on the tank band.

Apply Underbody protection on exposed body parts when needed.

34. Installing rubber seals

Install filler housing around top of filler pipe. Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.

Check that Spring clip (1) is in position. Oil mating surface on the rubber cover (2). Install cover. Install the drain hose (3) last of all, otherwise water or fuel will enter the cargo compartment. Install the ring (4). Install panels and carpets.

35. Verification of repair

Check that there are no leaks.

Check the function the fuel level sensor.