Wagon
Special Tools:^ 999 5448
Draining Fuel System
- Drain fuel system.
Preparations
- Remove cover above left wheel well
- Remove the floor panel behind the rear seat (fold down the backrests to access the nuts and pull panel forward and up).
- Remove cover over fuel tank unit, clean around unit and hose connectors.
- Remove hoses from fuel tank unit (undo the quick release connector by pushing the hose down while pulling the sleeve up).
NOTE: Avoid breathing in fuel vapor, use a protective mask.
Removing Fuel Pump Unit
- Remove hose clamp around collar.
- Remove fuel tank unit collar with tool 999 5448.
- Lift up fuel tank unit as far as the cable allows.
- Remove gasket.
NOTE: If the collar is not reinstalled within 12 hours it must be replaced as it will no longer fit properly and may leak.
Removing Pump From Fuel Tank
- Unhook the lower and then the upper pump mounting.
- Disconnect cables.
- Undo hose clamp at pump.
- Carefully pull the pump away from the hose.
- Replace pump.
Installing Pump In Fuel Tank
- Install pump wiring.
- Connect pump to hose and tighten hose clamp.
- Hook pump onto upper mounting.
- Press lower mounting into place.
Installing Fuel Tank Unit
- Use a new, dry gasket. Ensure that seal is correctly seated.
- Lubricate fuel tank unit mating surface with a thin layer of petroleum jelly.
- Carefully insert the fuel tank unit into the fuel tank, ensuring that the pump mounting is not damaged by the splash guard in the fuel tank.
- Check that the gasket does not fall into the fuel tank.
CAUTION: Engine may stall if the fuel tank unit is installed incorrectly.
Aligning Fuel Tank Unit With Fuel Tank
- Seat fuel tank unit stamped markings in the plastic joints on the tank.
- Install collar and tighten with tool 999 5448, do not damage nipples.
- Lock with the hose clamp.
Installing Hoses
- Install hoses, check that hoses cannot slip off the pipes on the fuel tank unit.
- Install cover over fuel tank unit.
Function Check
- Check fuel pump and gauge functions.
- Install cover above left wheel well.
- Install floor panel behind rear seat.