Removal and Replacement

Fuel tank, replacing

Special tools:
999 5622 Wrench 999 5622 Wrench
999 5666 Wrench 999 5666 Wrench
999 5972 FIXTURE 999 5972 Fixture

Fuel tank, draining
- Drain the fuel tank. See Draining the fuel tank Draining The Fuel Tank.

Removing from the top




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

Protective cover, removing




- Remove the left-hand protective cover
- Remove the two screws from the bracket for the parking brake cable. Pull the cable downward.

Connections, removing





Warning! Protective gloves and protective goggles must be used for the following operations. This is due to the risk of fuel spillage.

Remove:
- the fuel filler pipe
- the quick-release connector for the fuel filter, see Fuel filter, replacing Service and Repair.

Note! Wipe up any fuel spillage.

- The quick-release connector for the EVAP hose. Press in the lock. Pull off the hose.

Note! The clip must be left on the fuel line.

- the quick-release connector for the EVAP canister system. Press in the catch and pull off the hose
- the quick-release connector for the fuel line. Press in the catch and pull off the hose
- the quick-release connector for the EVAP system. Press in the catch and pull off the hose.

Fuel tank, removing




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

Installation

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.

Fuel tank components, transferring




- Detach the fuel lines and filter
- Transfer the fuel pump (FP) unit
- Transfer the canister unit
- Install the side and front heat shields. Tighten to 5 Nm.

Fuel tank, installing





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

- Install the fuel tank under the car.

Note! Check that the foam rubber pads on top of the fuel tank are correctly positioned.

- Secure the fuel lines in the mounting and on the fuel tank and heat shield. Tighten the holder
- Install the fuel tank straps. Finger-tighten the nuts
- Tighten the front nuts. Tighten to 25 Nm.

Connections, connecting




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

Note! Pull the quick-release connectors to check that they are secure.

- Connect the hose to the fuel filler pipe
- Install the clamp. Tighten to a maximum of 6 Nm
- Connect the quick-release coupling for the canister system.

Protective cover, installing




- Install the left-hand protective cover.
Position the protective cover. Tighten the screws.

Fuel pump components, installing




- Connect the connector
- Reinstall the protective cover
- Install the metal protective cover.

Warning! Ensure that the metal protective cover is correctly reinstalled. If the metal protective cover is not installed, the components underneath it may be damaged in the event of a collision. This would result in fuel spillage.

- Install the protective cover using four screws
- Reinstall the floor carpet
- Reinstall the rear seat
- Fill the fuel tank, see Draining the fuel tank Draining The Fuel Tank.

Finishing work
Check that the fuel line and fuel hoses are installed so that they do not rub or cause rattling
Start the engine. Check for leakage.
Continue to VIDA vehicle communication. Run a leak diagnostic.