Procedures

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.
- Remove fuel filler pipe ground lead from nut on fuel tank level sensor cover.
- 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.
- Disconnect the hose between the EVAP canister shut-off valve and air cleaner (ACL) from the clamp on the fuel tank.


Hint: Note position of hose in the clamp in case it opens. The hoses must be reinstalled in their original positions.





Installing New Fuel Tank Pressure Sensor
- Remove the screw
- Remove clamp

Note! The clamp will be reused.

- Disconnect hose.
- Remove cable harness.
- Install the new pressure sensor, route cabling as before.





Removing Clamp:
- Squeeze clamp with a pipe wrench. Hold in place.
- Pry apart with a small screwdriver.



Installing Clamp:
- Press in the clamp with a pipe wrench until it locks.





Installing Fuel Tank
- Raise the tank so that front holder can be installed to the bracket by pressing it until it locks into place.
- 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.
- Install EVAP canister shut-off valve hose in the clamp on the fuel tank.





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 all connectors.

Warning! Install fuel filler hose ground cable on level sensor cover.

- Install rubber bracket around wiring.
- Install panels, covers and carpets.