Fuel Tank, Pump and Gauge Sender Unit, 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


WARNING: Ensure that fuel handling precautions given in 01 - Introduction are strictly adhered to when carrying out following instructions.


CAUTION: before disconnecting any part of the system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system.


Remove
1. Raise vehicle on 4 post ramp.
2. Disconnect battery earth lead.
3. Depressurize fuel system. Service and Repair
4. Drain fuel tank completely. Service and Repair


NOTE: Fuel tank draining includes removal of fuel filler neck.


5. Position container beneath fuel filter to catch spillage.
6. Disconnect fuel feed pipe at rear of filter.
7. Disconnect fuel return pipe.







8. Remove and discard 'O' ring s. Plug all pipes and connections.
9. Support tank with jack.
10. Remove 3 nuts and 2 bolts securing tank cradle to floor pan.







11. Lower tank by 150 mm (6in) and disconnect 2 multiplugs from tank unit.







12. Lower tank assembly and remove from jack.


Disassemble
13. Remove tank from cradle.
14. Disconnect and remove breather hose from pressure sensor.
15. Disconnect feed and return pipes at tank unit and remove pipes.







16. Remove tank unit locking ring using LRT-19-009.


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


17. Remove tank unit using the lifting eye provided.


CAUTION: Do not lift the unit using the feed and return stubs as this may damage the stubs.


18. Remove tank unit sealing rubber and discard.







Reassemble
19. Fit new sealing rubber to tank unit.
20. Carefully fit tank unit and align aperture tab.
21. Tighten retaining ring to 35Nm (26 labor. ft) using tool LRT-19-009.
22. Fit fuel pipes and engage to tank clips.
23. Fit breather hose to pressure sensor.
24. Position tank in cradle.
25. Position tank assembly to jack.

Refit
26. Raise fuel tank assembly on jack until multiplugs can be connected.
27. Connect multiplugs to tank unit.
28. Raise tank and align to mountings. Secure tank with nuts and bolts.
29. Remove plugs from pipes and connections.
30. Connect and tighten fuel feed and return unions using new 'O' rings.
31. Lower vehicle.
32. Fit fuel filler neck. Service and Repair
33. Refill fuel tank.
34. Connect battery earth lead.