NHTSA ID Number: 10205692
Manufacturer Communication Number: SMB23140
TSB/Document Date: 2021-12-27
Summary
Service Campaign 140: Inspecting the Fuel Tank and Installing Rubber Dampers.
3+1*
945407
*1 extra rubber damper and flange nut required when the tank has a rear protective plate
SERVICE:
1.
Remove the protective plate on the left-hand
side of the fuel tank.
Page 1 of 16
2.
NOTE! On some models there is a rear protective
plate on the fuel tank, if so, remove the bolt in the
top right-hand corner as well and fold out the
protective plate slightly.
-
3.
Inspecting the mounting
Important! The fuel tank must be dry from all
moisture caused by rain or snow prior to
inspecting.
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NOTE! If fuel tank has cracks or leakage around
the attaching lugs then the tank must be replaced.
See page 5.
After replacing the tank or if it is considered OK
then the protective plate(s) must be refitted with
rubber dampers, see step 5.
A2303452
4.
Inspecting the mounting
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Page 2 of 16
5.
Installing the rubber dampers
Install the rubber dampers to the lugs on the
tank with the hexagon part of the damper
facing the tank.
Tighten the rubber damper so that the
hexagon just contacts with the lug surface,
then angle tighten an additional 45°(1/8 of a
turn).
A2303453
6.
Adjusting the protective plate
Cut off the shaded area as marked in the
illustration.
A = 173 mm
B = 135 mm
A2303460
7.
Installing the protective plate
Install the protective plate, tighten the nuts to
10 Nm.
A2303451
Page 3 of 16
8.
Installing the rubber damper to the rear
protective plate
NOTE! Only applies to cars with a rear protective
plate for the tank.
Install the rubber damper in the same way as
in the previous steps.
A2303454
Replacing the fuel tank (when necessary)
See the next page.
Page 4 of 16
Replacing the fuel tank (when necessary)
Cars with Emission code 0, 1, 2, 5, 6
Material
Fuel tank
Gasket
Gasket
Nut
Nut
Fuel level sensor*
Hose clamp
Hose
Hose clamp
Gasket
Protecting plate*
* Only applies to M/Y 1994
Quantity
1
1
1
1
1
1
1
1
2
1
1
Part Number
8631059
9447141
9447142
3501322
9142607
9480918*
989879
969106
9142053
6842188
9470378*
Cars with Emission code 3
, 4
Material
Fuel tank
Quantity
1
Part Number
8676687
Gasket
Gasket
Nut
Nut
Gasket
Hose
Hose clamp
Tensioning band
Tensioning band
Protecting plate
1
1
1
1
1
1
1
1
1
1
9447141
9447142
3501322
9142607
6842188
9480050
989879
9454593
9463196
3531436
Special tools
Description
Injector holder
Part Number
999 5533
Fixture
999 5972
999 5486
999 5485
Page 5 of 16
9.
Fuel tank, draining
NOTE! As the illustrations in this service
information are used for different model years and
or models, some variation may occur. However,
the essential information in the illustrations is
always correct.
Preparation
Disconnect the battery negative terminal.
See Note when disconnecting/connecting the
battery lead.
Note! Follow all Safety regulations for handling
fuel.
Draining fuel tank
NOTE! Always ensure that there is a ground
connection between the fuel intake and the fuel
filler pipe.
10.
Removing panels
5-door cars:
− Fold up the front floor hatch and fold
back carpet.
4-door cars:
− Fold forward right rear seat
Remove:
− cargo compartment carpet
− right wheel arch panel. Fold back the
corner of panel on variants with soft
panels
− covers over nuts to fuel pump (FP)
and level sensor.
NOTE! If carrying out work on fuel level sensor in
a 5-door model, fold the rear seat forward, remove
the front floor hatch screws (x 4) and pull hatch
backward.
A2300139
Page 6 of 16
11.
Disconnecting hoses
Separate connectors for fuel pump (FP) and
level sensor
Check color markings on hoses and pump.
Note! The delivery pipe is marked with yellow
tape. The pump has a corresponding color
marking.
Carefully disconnect quick-release
connectors on delivery and return hoses.
Use tool 999 5533 . Slide outer sleeve of
connector upward. Avoid squeezing sleeve.
999-5533
A2300516
12.
Removing fuel tank
Remove:
− spring clip that tensions the rubber
seal
− fuel cap and rubber seal.
A2300135
13.
Position mobile jack with fixture 999 5972.
Use flat lifting table to avoid damage to
internal tank components.
Undo tank retaining straps and lower tank
slightly.
999-5972
A2300144
Page 7 of 16
14.
Removing hoses
Disconnect EVAP system hose connector.
All hoses are secured in position by quickrelease clip on top of tank. Use a screwdriver
to release the upper end of the clip.
Lower tank.
A2300517
15.
Remove:
− the two fuel tank hose connectors
− the two screws on the flange retaining
the fuel filler pipe. Pull out pipe with
rubber seal and check valve.
A2300143
16.
Removing fuel pump (FP)
Remove nut securing level sensor. Use
wrench 999 5486.
Remove nut securing fuel pump. Use wrench
999 5485.
999-5486
999- 5485
A2300130
Page 8 of 16
17.
Lift out:
− fuel pump (FP) unit and level sensor.
Caution! Lift unit straight up. Do not grip pipe
connections with pliers or other sharp tool as
damage to connections may result in fuel leakage.
A2300518
18.
Installing fuel tank
NOTE! This step is only information.
Follow the method from step 19.
When installing a new fuel tank the following
components must be replaced with new parts
because the material swells. Failure to do so
may result in fuel leakage.
− Level sensor nut (white) (9142607)
− Level sensor nut seal (447142)
− Fuel pump (FP) nut (black) (3501322)
− Fuel pump (FP) nut seal (9447141)
− Fuel filler pipe seal (6842188)
Transfer and install the two covers from the
old fuel tank to the new one.
NOTE! On M/Y 1994, replace the side protective
plate PN 9470378.
NOTE! The protective plate must be adjusted
before installing see step 22.
A2300150
Page 9 of 16
19.
Modifying pipe from rollover valve
Cut the pipe on the new tank approx 25mm
past the bend. See the illustration.
A2303453
20.
Installing the rubber dampers
Install the rubber dampers to the lugs on the
tank with the hexagon part of the damper
facing the tank.
Tighten the rubber damper so that the
hexagon just contacts with the lug surface,
then angle tighten an additional 45°(1/8 of a
turn).
A2303453
21.
Installing the protective plate
Install the protective plate, tighten the nuts to
10 Nm.
A2303454
Page 10 of 16
22.
Adjusting the protective plate
Cut off the shaded area marked in the
Illustration.
A = 173 mm
B = 135 mm
A2303460
23.
Installing the protective plate
Install the protective plate, tighten the nuts to
10 Nm.
A2303451
24.
Installing fuel pump (FP)
Install:
− rubber seal on fuel pump (FP) unit.
Lubricate the inside and top of the seal
with petroleum jelly.
− fuel pump (FP) unit
NOTE! Check the alignment of the fuel pump (FP)
unit, see illustration.
A2303463
Page 11 of 16
25.
Install fuel level sensor
Install a new level senor on M/Y 1994:
emission code 0, 1, 2, 5, 6
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TSB/Document ID: SMB23140
Replacement Service Bulletin Number:
MFR Communication Date: 2015-12-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
MFR Component System:
MFR Component Subsystem:
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