Fuel Tank: Service and Repair

FUEL TANK REPLACEMENT





Drain Fuel Tank
^ Use drainage unit P/N 9812270, 9812273 and 9812282. Insert hose in filler pipe.

NOTE: Hose must be inserted at least 1 meter to ensure immersion in fuel. End of hose may have to be cut at an angle to get past all sharp edges.





Removal of Panels

5-door Models:
^ Tilt forward right-hand rear seat.

4-door models:
^ Raise front floor cover and fold back carpet.
^ Remove:
- Luggage compartment carpet and right-hand wheel housing panel. It is sufficient to fold back a corner of the panel on certain variants with a soft panel.
- Covers above fuel pump and fuel level transmitter nuts.

NOTE: If carrying out work on fuel level transmitter in a 5-door model, fold the rear seat forward, remove the front floor cover screws (four) and pull cover backward.





Disconnection of Hoses
^ Open fuel pump and fuel level transmitter connectors. Check color markings on hoses and pump.

NOTE: Delivery hose is marked with yellow tape, corresponding to color code on pump.

^ Carefully disconnect quick-release couplings on delivery and return hoses.
^ Use tool P/N 9995533. Slide outer sleeve of coupling upward without squeezing sleeve.





Removal of Fuel Tank
^ Remove:
- Circlip securing filler housing (rubber element).
- Filler cap and filler housing.
^ Position mobile jack and lifting fixture P/N 9995972 under tank.
^ Use flat lifting table to avoid damage to tank internals. Undo tank retaining straps and lower tank slightly.





Removal of Hoses
^ Undo EVAP system connections.
^ All hoses are secured in position by quick-release clip on top of tank. Use screwdriver to undo top end of clip.
^ Lower tank.





^ Remove / Disconnect:
- Hose connections (two) at tank.
- Screws (two) securing filler pipe clamp. Withdraw pipe, complete with rubber seal and non-return (flap) valve.





Removal of Fuel Pump Unit
^ Remove nuts securing:
- Level transmitter, using tool P/N 9995486.
- Fuel pump unit, using tool P/N 9995485.





^ Lift out fuel pump unit and level transmitter.

NOTE: Lift units straight upwards. Do not grip pipe connections with pliers or other sharp tool as damage to connections may result in fuel leakage.

^ Remove seal.





Installation of Fuel Tank
^ When installing a new tank, the following components must be replaced due to swelling of the material. Failure to do so may result in fuel leakage.
- Level transmitter nut (white).
- Level transmitter nut seal.
- Fuel pump unit nut (black).
- Fuel pump unit nut seal.
- Filler pipe seal.
^ 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.





Installation of Fuel Pump Unit
^ Install fuel pump unit and level transmitter seals, grease top and inside of seals with petroleum jelly.





^ Install fuel pump unit.
^ Install level transmitter.

NOTE: Ensure that pump unit and level transmitter are positioned as shown in figure.

^ Ensure that pump heater connection faces towards right and level transmitter lead towards left of car.

NOTE: Engine may stop if fuel pump unit is installed incorrectly.





Installation of Nuts
^ Tighten large nut to 40 Nm (29.5 ft lb).
^ Tighten small nut to 30 Nm (22 ft lb).
^ Check level transmitter wiring as shown in illustration.





Installation of Filler Pipe
^ 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 flap in position against pipe.
^ Press pipe firmly into seal so that it slides into position.
^ Install filler pipe clamp.
^ Install screws. Tighten to 10 Nm (7.4 ft lb).





Installation of Hoses
^ Reconnect hoses to tank. (See illustration for correct location).
^ Tighten clips to 3.5 Nm (2.6 ft lb).
^ Turn clips to avoid rubbing against floor.

NOTE: Check connection on top of tank with particular care.





Installation of Fuel Tank
^ Place tank and retaining straps on jack.
^ Use same fixture and lifting table as when removing tank.
^ Lift tank into position and tighten rear strap.





^ Push tank forward as far as possible. Center tank as illustrated to ensure that level transmitter nut (white) is clear of hole.
^ Tighten screws securing front strap.
^ Press hose retaining clip onto strap.





Installation of Rubber Seals
^ 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) last, ensuring that tube is on inside of seal (1), otherwise water (or fuel) may enter luggage compartment. Install circlip (4).
^ Install panels, covers and carpets.