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Fuel Tank Replacement - 1.6L LLU > < Charge Air Bypass Regulator Solenoid Valve Replacement

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Fuel Tank Fuel Pump Module Replacement (1.6L LLU)

Special Tools

•  EN-6015   Plugs
•  EN-48279   Main Fuel Pump Locking Ring Remover/Installer

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the fuel tank. Refer to Fuel Tank Replacement .

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2. Disconnect the fuel feed pipe (2) and the fuel return pipe (3) from the fuel tank fuel pump module (5).
3. Close the fuel tank vent pipe (2) and the fuel feed pipe (3) with EN-6015   plugs .
4. Disconnect the fuel tank fuel pump module wiring harness (1) from the fuel tank fuel pump module (5).

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5. Install the EN-48253   remover/installer (1) to the fuel pump module lock ring (2).

Note:  Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
6. Using the EN-48253   remover/installer and a long breaker-bar, rotate the lock ring in a anticlockwise direction in order to unlock the lock ring.

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7. Remove the fuel tank fuel pump module lock ring (4).
8. Remove the fuel tank fuel pump module (5).

Note:  Lift the fuel tank fuel pump module up slightly.
9. Remove and discard the fuel pump module seal (6).

Installation Procedure


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1. Install a NEW fuel pump module seal (6).
2. Install the fuel tank fuel pump module (5)
3. Install the fuel tank fuel pump module lock ring (4).

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4. Install the EN-48253   remover/installer (1) to the fuel pump module lock ring (2).

Note:  Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
5. Using the EN-48253   remover/installer and a long breaker-bar, rotate the lock ring in a clockwise direction in order to lock the lock ring.

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6. Remove the EN-6015   plugs from the fuel tank vent pipe (2) and the fuel feed pipe (3).
7. Connect fuel tank fuel pump module wiring harness (1) to the fuel tank fuel pump module (5).
8. Connect the fuel feed pipe (2) and the fuel return pipe (3) to the fuel tank fuel pump module (5).
9. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Tank Replacement - 1.6L LLU > < Charge Air Bypass Regulator Solenoid Valve Replacement