Removing
All cars
1. Disconnect the wire "masses" from the battery. For more information refer to Specification.
2. Drain the fuel from the fuel tank. For more information refer to Emptying the fuel tank (19.55.02)
3.
WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.
Raise and support the vehicle.
4. Remove the fuel tank heat shield. Remove 3 bolts and remove 2 nuts.
5.
CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
Disconnect the fuel filler neck from the fuel filler hose.
- Remove the tamper-proof cover.
- Remove and discard hose clamp.
6.
CAUTION: Secure the assembly to the transmission jack.
Lower the fuel tank with a transmission jack. Turn out 5 bolts.
7. Release the parking brake cable emergency release cable. Release from 4 clips.
8.
NOTE: Remember the position of the part.
Disconnect the fuel tank vent line and fuel line.
- Remove holders.
- Release from clamps.
- Remove self-adhesive tape.
9.
CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
Disconnect the 2 fuel tank vent lines. Release the clamp.
Vehicles with fuel-fired auxiliary heater
10.
CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
Disconnect the fuel line from the fuel-fired auxiliary heater. Release the clamp.
All cars
11.
CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
Disconnect 2 fuel lines. Release 2 clips.
12. Disunite an electric socket of the module of the fuel pump.
13. Remove the fuel tank.
14.
NOTE: Do not proceed with further disassembly if the part is being removed only for access.
With assistance, remove the fuel tank from the transmission jack.
15.
CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
NOTE: Remember the position of the part.
Loosen the fuel pump module access flange.
- Loosen the screw.
- Remove clamp.
16.
CAUTION: Before disconnecting or dismantling parts, make sure that the area around the contact surfaces and connections is clean. Plug all open connections to avoid contamination of the system.
Remove the fuel pump module access flange.
- Disconnect the ventilation line.
- Disconnect the fuel supply line.
- Disconnect 3 electrical connectors.
- Remove and discard the O-ring.
17. Remove the fuel pump module.
- Release the tape.
- Release the fuel pressure regulator.
- Disconnect 2 fuel lines.
18. Remove the front fuel tank level sensor.
- Release the wire.
- Release the clamp.
19. Remove the fuel tank bracket.
- Remove 2 clips.
- Turn out two bolts.
- Remove the mounting plate.
Installation
All cars
1. Install the fuel tank bracket.
- Install the base plate.
- Install clamps.
- Tighten the bolts (tightening torque 10 Nm).
- Lock the clamp.
- Fasten the wire.
3. Install the fuel pump module.
- Connect the fuel lines.
- Secure with tape.
- Attach the fuel pressure regulator.
- Clean the contact surfaces of the parts.
- Install a new seal.
- Connect 3 electrical connectors.
- Connect the fuel supply line.
- Connect the ventilation line.
CAUTION: Make sure the seal is installed correctly.
NOTE: Align the part to its original position.
Install the fuel pump module access flange.
- Install clamp.
- tighten screw (tightening torque 4 Nm).
6. With assistance, place the fuel tank on the transmission jack.
7. Put the fuel tank on the car.
8. Connect fuel lines. Fasten with a clip.
Vehicles with fuel-fired auxiliary heater
9. Connect the fuel line of the additional fuel fired heater. Fasten with a clip.
All cars
10. Connect the ventilation lines. Fasten with a clip.
11. Dock the electrical connector.
12. Fix the vent line and fuel line.
- Fasten with clips.
- Install holders.
- Install self-adhesive tape.
14. Install the fuel tank. Tighten the bolts (tightening torque 45 Nm).
15.
CAUTION: Tighten the tamper-proof clamp until the hex head breaks off.
Attach the fuel tank filler neck. Install a new clip.
16. Install the fuel tank heat shield.
- Tighten the bolts (tightening torque 5 Nm).
- Tighten nuts (tightening torque 3 Nm).
18. Remove air from the fuel system. For more information, refer to Bleeding the Low Pressure Fuel System (19.50.07)
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