For 1990-2009 cars

#### Special Tools

SA9805E /KM-796-A Fuel Line Separator

### Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

Important:

• | The fuel tank must be drained with a suitable, commercially-available fuel removal unit and suction hose - follow safety regulations and national legislation. The fuel tank is fitted with a refill limit float valve. This is located on the filler neck in the fuel tank. To prevent damaging the refill limit float valve, a suitable suction hose must be used.

• | In the presence of fuel vapors or escaping fuel - observe safety regulations and national legislation. Store drained fuel in a suitable, sealable container.

1. Open the hood.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the battery.

• | Disconnect the ground clamp from the negative terminal.

• | Remove the nut.

3. Remove the right rear wheel.
4. Raise the vehicle halfway.
5. Remove the right rear wheel.
6. Remove the right rear wheel housing inner panelling.

Remove the 2 nuts (1) and the 2 bolts (2).

7. Disconnect the wiring harness of pressure sensor (atmospheric pressure) (1).

• | Disconnect the wiring harness plug (2).

• | Remove the 3 cable ties (3).

8. Raise the vehicle halfway.
9. Disconnect the wiring harness of pressure sensor (atmospheric pressure) (1) from the fuel filler tube (2).

Remove the 3 cable ties (3).

10. Remove the complete exhaust system. Refer to Exhaust System Replacement .
11. Disconnect the wiring harness plug of fuel tank fuel pump module (1).
12. Remove the vent hose (3) from vent pipe (1).

Disconnect the quick-release fitting (2) using SA9805E /KM-796-A .

13. Disconnect the fuel filler tube from fuel tank.

Release the clamp (1).

14. Remove the rear fuel lines (3, 5) from middle fuel lines (1, 2) .

• | Disconnect the 2 quick-release fittings.

• | Press the release (4).

15. Remove the parking brake cable from bracket (1) in 7 places.
16. Retract the jack.
17. Remove the 2 fuel tank holding straps.

Remove the 4 bolts (1).

Important: Wiring harness must be passed over rear axle.

18. Remove the fuel tank.
19. Remove the rear fuel pump fuel hose (1).

• | Disconnect the quick-release fittings (2).

• | Remove the rear fuel pump fuel hose from the bracket (3).

### Installation Procedure

1. Install the rear fuel pump fuel hose.

• | Connect the quick-release fittings.

• | Install the rear fuel pump fuel hose at the bracket.

2. Position the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

3. Connect the 2 fuel tank holding straps.

Tighten
Tighten the 4 fuel tank holding strap bolts to 23 N·m (17 lb ft).

4. Extend the jack.
5. Install the parking brake cable to the bracket in 7 places.
6. Install the rear fuel lines to the middle fuel lines.

Connect the 2 quick-release fittings.

7. Connect the fuel filler tube to fuel tank.

Tighten
Tighten the clamp to 3.5 N·m (31 lb in).

8. Connect the vent hose to the vent pipe.
9. Connect the quick-release fitting.
10. Connect the wiring harness plug of the fuel tank fuel pump module.
11. Install the complete exhaust system. Refer to Exhaust System Replacement .
12. Connect the wiring harness of the pressure sensor (atmospheric pressure) to the fuel filler tube.

Connect the 3 cable ties.

13. Lower the vehicle halfway.
14. Connect the wiring harness of pressure sensor (atmospheric pressure).

• | Connect the wiring harness plug.

• | Connect the 3 cable ties.

15. Install the right rear wheel housing inner paneling.

Tighten

• | Tighten the 2 rear wheel housing inner paneling nuts to 2.5 N·m (22 lb in).

• | Tighten the 2 rear wheel housing inner paneling bolts to 2.5 N·m (22 lb in).

16. Mount the right rear wheel.
17. Lower the vehicle halfway.
18. Install the right rear wheel.

Tighten
Tighten the right rear wheel bolt to 110 N·m (81 lb ft).

19. Connect the battery.

Connect the ground clamp to the negative terminal.

Tighten
Tighten the ground clamp nut to 5 N·m (44 lb in).

20. For programming procedures, refer to Control Module References .
21. Close the hood.