Fuel Tank, Replacing

Special Tools
999 5622
999 5666
999 5972

Draining fuel tank
- Drain fuel tank according to Draining The Fuel Tank.

Disconnecting upper side





- Fold the rear seat forward
- Remove floor carpet
- Remove four screws and protective plate
- Remove metal protection cover
- Disconnect connector.

Removing splash guards
- Remove left splash guard
- Remove the two bolts from the parking brake cable bracket. Pull cable down.

Removing connections

Warning Protective gloves and protective goggles should be used for the following operations because of the risk of fuel spillage

Remove:
- fuel filler hose
- fuel filter quick-release connector, see Replacing fuel filter, refer to Fuel Filter, Service and Repair.

Note! Wipe up any spilled fuel.

- EVAP hose quick-release connector. Press in lock and pull off hose.

Note! Leave clips on the fuel line.

- purging system quick-release connector, press in lock and pull off hose
- fuel line quick-release connector press in lock and pull off hose
- EVAP system quick-release connector press in lock and pull off hose.

Removing fuel tank





- Apply rust solvent to components
- Slacken off lock nuts
- Support the fuel tank using a mobile jack with fixture 999 5972
- Remove nuts at the front and rear and remove tank straps
- Lower the fuel tank slightly and remove wiring bracket and wiring by the fuel tank and at the right heat shield
- Lower and remove the fuel tank.

Installing
Transferring fuel tank components





- Disconnect fuel lines and filter
- Transfer Fuel Pump (FP) unit
- Transfer EVAP canister unit
- Side and front heat shields. Tighten to 5 Nm.

Installing fuel tank

Note! Tighten rear nuts until the inner edges of the straps are in contact with the car body.

- Install the fuel tank under the car.

Note! Check if foam pads on top of fuel tank are correctly fitted.

- Install the wiring in the bracket and on the fuel tank and heat shield. Tighten holders

- Install the straps and finger-tighten nuts
- Tighten front nuts. Tighten to 25 Nm.

Connecting connections





- Clean all components
- Connect quick-release connectors on the EVAP and fuel lines.

Note! Check that they are secure by pulling them.

- Connect hose to fuel filler pipe
- Install the clamp. Tighten to 6 Nm maximum
- Connect purging system quick-release.

Installing splash guard





- Install left splash guard. Secure splash guard and tighten bolts.

Installing fuel pump (FP) components





- Connect connector
- Reinstall splash guard
- Install metal protection cover.

Warning Be sure to reinstall the metal protection cap. Failure of this cap may result in these components being damaged in an impact and possibly causing fuel leakage.

- Install protective plate with four screws
- Reinstall carpet
- Reinstall rear seat
- Fill fuel tank, see Draining the fuel tank.

Finishing
Check that the fuel line and fuel pipes are installed so that they do not rub or cause rattling
Start the engine and check for fuel leakage.
Proceed to VADIS vehicle communication and carry out the leak diagnostic test.