Fuel Tank Pressure Sensor: Service and Repair

Special tools: 999 5972





Preparations
5-door models:
- Remove all floor hatches and fold back carpet.
- Remove cover over fuel pump (FP) unit.

4-door models:
- Fold forward rear right back seat.
- Remove luggage compartment carpet.
- Fold back corner of wheel housing panel at shock absorber mounting.
- Remove cover over fuel pump unit.









Disconnecting Connectors
- Disconnect all connectors on the bracket.
- Remove rubber bracket around wiring.
- Ensure that all cables routed through the fuel pump unit hole are free to follow the fuel tank when it is lowered.





Removing Fuel Filler Pipe
- Remove circlip securing rubber seal.
- Release rubber seal from bodywork.





Removing Fuel Tank
- Position mobile jack with fixture 999 5972 under fuel tank, check that the lifting platform is flat so as not to damage the fuel tank.
- Undo tank retaining straps and lower tank slightly.





Removing Front Bracket
- Remove the entire mounting from the bracket by pulling it towards the right of the car.





Installing New Fuel Tank Pressure Sensor
- Remove old tank pressure sensor.
- Install the new pressure sensor, route cabling as before.

NOTE: It is important to install the tank pressure sensor hose correctly to avoid fuel leakage.





Installing Fuel Tank
- Raise the tank so that front mounting can be installed to the bracket.
- Ensure that cabling routed through the fuel pump unit hole will not be trapped when the fuel tank is installed.
- Raise the fuel tank and fix it to the bodywork.





Installing Fuel Filler Pipe Rubber Cover
- Check that the inner rubber seal is correctly seated and that the drain pipe is inside the inner seal.
- Check that circlip (1) is in position.
- Lubricate rubber cover sealing surfaces (2) with petroleum jelly.
- Install rubber cover (ensure that it is correctly positioned in relation to bodywork).
- Install circlip (4) and drain pipe (3).
- Connect fuel pump and level sensor connectors. Tank pressure sensor and ABS sensors.
- Install rubber bracket around wiring.
- Install panels, covers and carpets.