Removal and Replacement

Fuel tank

Special tools:
999 5972 FIXTURE 999 5972 Fixture
999 5972 FIXTURE 999 5972 Fixture

Note! 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.

Preparatory work

Drain the fuel system. See: Fuel system pressure release Fuel System Pressure Release.
Drain the fuel tank. See: Fuel tank draining Service and Repair.

Removal

Removing the carbon filter container

Note! Make sure that no cables/hoses are loaded or trapped when raising the sub-frame.

Remove the carbon filter container. See: Charcoal filter Service and Repair.
Suspend the rear suspension using the 2 rear screws. Suspend the mufflers in their rear rubber mountings.

Removing the exhaust system





Remove:
- the 2 x flanged joint nuts between the three-way catalytic converter (TWC) and front exhaust pipe
- the 2 x rubber mountings for the front exhaust pipe.
Hang the exhaust system to one side.

Removing the air baffle left-hand





Remove:
- the plastic nuts x 2 (1)
- the screw x 1 (2)
- the air baffle.

Removing the rear heat deflector plate





Remove:
- the 5 plastic nuts
- the heat deflector plate.

Removing the fuel tank




Detach the cable harness from the tank.





Remove:
- the clamp (1)
- the fuel filler hose
- the clamp (2)
- the hose from the T-connector.




Remove the fuel hose.
Plug the ends of the hose and pipe.





Note! Be careful to not trap any cables/hoses when lowering the tank.

Place a mobile jack with: 999 5972 FIXTURE 999 5972 Fixture under the fuel tank.
Remove the 3 x screws for the fuel tank straps. Remove the tank retaining straps. Lower the tank slightly.
Disconnect the level sensor connector.
Lower the tank.

Transferring components

Note! Transfer the fuel pump (FP) to the new fuel tank. See: Fuel pump Service and Repair

Installation

Note! For tightening torques, see Specifications. Tightening Torque

Installing the fuel tank
Place the tank on the mobile jack together with fixture: 999 5972 FIXTURE 999 5972 Fixture.
Raise the tank so that it is 30 cm from the top.

Install:
- the connector to the level sensor
- the hoses/pipes in the guides on the right-hand side of the tank.
Lift up the fuel tank.

Install:
- the tank retaining straps. Use the 3 x M8 screws
- the fuel filler hose with the clamp. Tighten
- the hose to the T-connector. Use a new clamp
- the cable harness in the clamps.

Installing the rear heat deflector plate

Install:
- the heat deflector plate
- the 5 plastic nuts

Installing the air baffle left-hand





Install:
- the air baffle
- the plastic nuts x 2 (1)
- the screw, x 1 (2).

Installing the exhaust system

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair

Install:
- the exhaust system using the new flange package
- the 2 x M10 nuts
- the rubber mountings.

Installing the carbon filter container
Install: 998 5972 JACK 998 5972 Jack with: 999 5972 FIXTURE 999 5972 Fixture against the sub-frame.
Remove the rear screws for the sub-frame. Lower the sub-frame approximately 4 cm.
Install the carbon filter container. See: Charcoal filter Service and Repair.

Finishing

Top up the fuel.
Install the fuse for the fuel pump (FP).