Fuel Tank, Pump and Gauge Sender Unit, Pre Advanced EVAPS

Service repair no - 19.55.01 - Fuel Tank
Service repair no - 19.45.08 - Fuel Pump
Service repair no - 88.25.32 - Fuel gauge Tank Unit

Remove
1. Disconnect battery negative lead.
2. Petrol Models Only: Depressurize fuel system. Service and Repair
3. Remove contents of fuel tank into an approved closed container.
4. Remove fuel filler neck. Service and Repair
5. Raise vehicle on four post lift.
6. Position container beneath fuel filter to catch spillage.
7. Petrol Models Only: Disconnect feed pipe from fuel filter.
8. Diesel Models Only: Disconnect feed pipe at connection, forward of fuel tank.







9. Disconnect return pipe, forward of tank.
10. Plug pipes and connections.
11. Support tank with jack.
12. Remove 3 nuts and 2 bolts securing tank cradle to floor pan.







13. Lower tank by 150mm. Disconnect multiplug from fuel tank unit.







14. Lower tank assembly. Remove from jack.
Do not carry out further dismantling if component is removed for access only.

Disassemble
15. Remove tank from cradle.
16. Slacken clip. Remove fill breather pipe from tank unit.







17. Disconnect feed and return pipes from the tank unit.
18. Remove tank unit retaining ring using LRT-19-001. Remove assembly from tank.







WARNING: A quantity of fuel will be retained in the unit, care must be taken to avoid excessive spillage during removal.


19. Remove lank unit sealing rubber and discard.

Reassemble
20. Fit new sealing rubber.
21. Fit tank unit. Align location marks.
22. Fit retaining ring using LRT-19-001.
23. Connect fuel feed and return pipes to tank unit. Tighten to 16 Nm. (12 labor. ft)
24. Secure pipes to fuel tank clips.
25. Position fill breather pipe to tank unit. Secure with clip.
26. Position tank in cradle.

Refit
27. Raise fuel tank assembly on jack until multiplug can be connected to tank unit.
28. Raise tank. Align cradle mounting points. Secure with nuts and bolts.
29. Remove plugs from pipes and connections.
30. Petrol Models Only: Using new 'O' ring , connect fuel spill return pipe. Tighten to 16 Nm (12 labor.ft).
31. Petrol Models Only: Using new 'O' ring , connect fuel feed pipe to filter. Tighten to 20 Nm. (15 labor. ft)
32. Diesel Models Only: Connect fuel feed and return pipes.
33. Lower vehicle.
34. Refit fuel filler neck. Service and Repair
35. Refill fuel tank.
36. Reconnect battery negative lead.