9-3 1999

Removal & Installation

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2.0L Engine



  1. Before servicing the vehicle, refer to the precautions.
  2.  
  3. Empty the fuel from the tank through the fuel filler pipe using the appropriate equipment.
  4.  
  5. Place the car on a lift. Make sure the rear right-hand lift-arm pad is placed as far out as possible to facilitate the work.
  6.  
  7. Raise and safely support the vehicle securely.
  8.  
  9. Detach the rubber hoses from the tank, using 83 95 261 Fuel line tool to disconnect the thin bleeder hose, and plug the tank with 83 94 777 Fuel tank plug.

    Click image to see an enlarged view

    Fig. Detach the rubber hoses from the tank (4), using 83 95 261 Fuel line tool to disconnect the thin bleeder hose, and plug the tank with 83 94 777 Fuel tank plug

  10.  
  11. Remove the protective cover in front of the fuel filter and carefully tap the filter container away from its mounting. Use a drift.
  12.  
  13. Lift down the filter container.
    WARNING
    Be careful with the wiring harness for the filter pre-heating and the auxiliary heater fuel pump.

  14.  
  15. Carefully clamp the soft section of the fuel hoses with 30 07 739 Pinch-off pliers and disconnect the hose between the tank and filter.

    Click image to see an enlarged view

    Fig. Remove the protective cover (5), carefully clamp the soft section of the fuel hoses with 30 07 739 Pinch-off pliers (7) and disconnect the hose between the tank and filter (6)

  16.  
  17. Detach the delivery hose and the connector from the auxiliary heater fuel pump.

    Click image to see an enlarged view

    Fig. Detach the delivery hose and the connector (8) from the auxiliary heater fuel pump

  18.  
  19. Support the tank on a column lift and then undo the nuts on the straps securing the fuel tank without completely unscrewing them. Unhook the straps.

    Click image to see an enlarged view

    Fig. Support the tank on a column lift and then undo the nuts (9) on the straps securing the fuel (11) tank without completely unscrewing them. Unhook the straps

  20.  
  21. Move the left-hand handbrake cable out of the way.
  22.  
  23. Carefully lower the tank, right-hand side first, until the top becomes visible.
    NOTE
    Detach the fuel lines from the snap fasteners on the tank and the body so that they are not creased or bent.

  24.  
  25. Unplug the connectors on the wiring harness, not on the tank.

    Click image to see an enlarged view

    Fig. Unplug the connectors (12) on the wiring harness, not on the tank. Detach the return line (13) from the fuel tank

  26.  
  27. Detach the return line from the fuel tank.
  28.  
  29. Lower the tank to working height.
  30.  

To install:

  1. Inspect the O-rings before fitting them on the fuel lines. Replace them if necessary.
  2.  
  3. Raise the tank.
  4.  
  5. Connect the return line to the fuel tank.
  6.  
  7. Plug in the connectors.
  8.  
  9. Support the tank on a column lift and hook the tank straps to the body.
  10.  
  11. Press the fuel lines into their snap fasteners on the tank and the body. Lift the tank, making sure not to pinch the electrical wiring between the tank and the body, and tighten the nuts on the straps.
    NOTE
    Position the left-hand handbrake cable between the strap and the tank.

  12.  
  13. Remove the plug from the tank and connect the rubber hoses.
  14.  
  15. Connect the delivery hose and connector to the auxiliary heater fuel pump.
  16.  
  17. Connect the hose between the tank and the filter, remove the hose clamp pliers and fit the fuel filter container.
    WARNING
    Be careful with the wiring harness for the filter pre-heating and the auxiliary heater fuel pump.

  18.  
  19. Fit the protective cover in front of the fuel filter and Lower the vehicle.
  20.  
  21. Start the engine and check the integrity of the system.
  22.  
  23. If the engine stalls due to air in the fuel system, the system must be bled.
  24.  

 
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