Draining the Fuel Tank

Fuel Tank, Draining

Special tools: 999 5720, 999 5721

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.

WARNING: RISK OF EXPLOSION!!! THE USE OF A FRESH AIR MASK IS RECOMMENDED.

Insert the heavy duty hose 1.3 meters into the fuel filler pipe, measured from the edge of the opening of the filler pipe.

Pump until air comes out.

Remove the outer rear seats. See Upholstery backrest cushion outer (second row). Remove the center rear seat. See Upholstery backrest cushion center (second row), replacing. Fold the carpet back.

Remove:







- the ventilation pipe (1)
- the insulation block (2)
- the insulation block (3).

Remove:







- the 6 seat frame screws (1)
- the 2 seat frame screws (2).

Raise the rear edge of the seat frame approximately 25 mm. Position a block between the frame and the transmission tunnel.

Cover the area around the cover and between the doors with absorbent material.

CAUTION: Ensure that there is no risk of dirt getting into the tank.

Removing the cap over the level sensor







Remove the covers (1.2) over the fuel tank units.

Disconnect the level sensor connector (3).

Remove the hoses from the right-hand level sensor.

Draining the fuel tank







Special tools: 999 5720.

Clean the area around the fuel tank unit thoroughly.

Open the right-hand level sensor. Insert the heavy duty hose and suck out the remains from the bottom of the right-hand side of the fuel tank.

Connect hose 999 5721 to the heavy duty hose.

Suck out the remains from the bottom of the level sensor reservoir.

Carefully remove the overflow pipe from the reservoir.







Remove the thin hose (999 5721 ) from the heavy duty hose. Connect the thin hose to the overflow pipe. Use a hose clamp.

Pump until a lot of air comes out.

Open the left-hand level sensor. Insert the heavy duty hose and suck out the remains from the bottom of the left-hand side of the fuel tank.

Installing the right-hand level sensor







Place the overflow pipe approximately half a centimeter to the left-hand side.

Grip around the right level sensor reservoir. Pinch the level sensor reservoir so that the float is held in its lowest position.

Lower the reservoir carefully while rotating it backwards around the front-rear shaft on the float.

Install the overflow pipe on the reservoir.

Installing the left-hand level sensor
Install a new O-ring.

Press the left level sensor down so that the row of protruding cables runs along the car.

Check that the O-ring is not trapped.

Tighten the screw. Tighten to 60 Nm.

Wipe up any fuel spillage.

Position the wiring in the cut-out in the rubber ring







NOTE: Check that the arrow on the cover is between the markings on the tank. If the arrow is outside the markings the fuel gauge sensor will give an incorrect value and the float may catch against the inner wall of the tank. If not: Slacken off the screw and adjust the position of the sensor. Tighten as above.

Right-hand level sensor, continued
Install a new O-ring.

Press the right-hand level sensor down so that the fuel line connections are pointing forwards and to the right.

Check that the O-ring is not trapped.

Tighten the screw. Tighten to 60 Nm.

Install the hoses on the level sensor.

Wipe up any fuel spillage.

Position the wiring in the cut-out in the rubber ring.







NOTE: Check that the arrow on the cover is between the markings on the tank. If the arrow is outside the markings the fuel gauge sensor will give an incorrect value and the float may catch against the inner wall of the tank. If not: Slacken off the screw and adjust the position of the sensor. Tighten as above.

Install the covers over the level sensors. Tighten the screws.

Connect the wiring and the connectors.

Remove the block from under the seat frame

Install:
- the 8 seat frame screws. Tighten to 50 Nm
- the 2 seat frame screws. Tighten to 24 Nm.

Fold the carpet down

Install:
- the center rear seat. See Upholstery backrest cushion center (second row), replacing
- the outer rear seat. See Upholstery backrest cushion outer (second row).