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Fuel Pump > < Fuel Tank and Lines

Ka 1997 (09.1996-)

Fuel Tank and Lines - Fuel Tank Ka 1997 (09/1996-)
Removal and Installation

General Equipment
Fuel tank draining equipment

Removal

WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
CAUTION:
CAUTION:Disconnect the battery negative lead.
NOTE:
NOTE:It will be necessary to raise the vehicle in order to carry out this procedure.
  1. Drain the fuel tank using proprietary fuel tank draining equipment.
  1. Raise the vehicle.

  1. Detach the exhaust system from the two centre rubber insulators.

  1. Detach the exhaust system from the rear rubber insulator.
    • Allow the exhaust system to be supported by the rear suspension assembly.

  1. Remove the exhaust heat shield (seven nuts).

  1. Disconnect the fuel tank vent pipe from the fuel tank (one clip).

  1. Disconnect the outlet pipe from the fuel filter.

  1. Disconnect the evaporative emission canister pipe from the fuel tank vent valve.

  1. Detach the fuel tank vent valve from the evaporative emission canister bracket.

  1. CAUTION:
    CAUTION:When supporting the fuel tank, use a suitable packing material to prevent damage to the underside of the fuel tank.
    Support the fuel tank with a suitable jack.

  1. Remove the four fuel tank retaining bolts.

  1. Partially lower the fuel tank.

  1. Disconnect the fuel return pipe from the fuel tank.
    • Fuel return pipe connectors are red or are identified by a red band.

  1. CAUTION:
    CAUTION:When disconnecting multiplugs do not pull on the wiring; pull on the multiplug body.
    Disconnect the fuel pump/sender unit multiplug.

  1. Remove the fuel tank.

  1. Remove the fuel tank vent valve.

Installation

  1. Refit the components in reverse order.
    • Lubricate the fuel tank filler pipe seal with clean engine oil to aid fuel tank installation.

Fuel Pump > < Fuel Tank and Lines