1.6L Diesel: Removal

1. Place the vehicle on a lift.
2. Open the cover of the fuse box in the engine compartment and remove the fuse F21 (15 A) of the fuel pump.
3. Start the engine and run until the fuel in the lines is depleted.
4. Install the fuse removed earlier and close the fuse box cover.
5. Disconnect and isolate the negative battery cable.
6. Remove the muffler assembly. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
7. Remove the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .

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8. Remove the screws and the access cover to the fuel pump (1).

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9. Disconnect the fuel pump module wire harness connector (1).
10. Disconnect the fuel supply line quick connect fitting (2).
11. Disconnect the fuel return line quick connect fitting (3).

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12. Disconnect the vent line quick connect fitting (1).

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13. Remove the toothed washer (1) securing the heat shield to the body.

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14. Open the retaining clips and disengage the rear brake lines (1).

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15. Open the clips and release the right rear brake line (1).

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16. Place a suitable hydraulic lift (1a) under the tank and remove the front bolts (1b).

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17. Remove the rear fuel tank support bracket bolts (1).
18. Disconnect the quick coupling of the vapor hose from the fuel tank to the canister.

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19. Lower the tank and unhook the fuel supply and return lines from the retaining clips (1).

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20. Lower the hydraulic lift and remove the fuel tank (1).

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21. Install the 2000002100 (EMEA) or (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (NAFTA) tool (1a) and remove the lock nut from the fuel pump assembly (1b).

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22. Remove the fuel pump assembly (1).

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23. Remove the O-ring seal on the tank (1).

INSTALLATION 

1. Install a NEW  O-ring seal on the fuel tank.

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2. Install the fuel pump module, taking care to match the references (1a), (1b) and (1c) as indicated.
3. Securely tighten the fuel pump assembly lock nut.
4. Using the hydraulic lift, put the fuel tank into position.
5. Engage the fuel delivery line with the retaining clips.

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6. Install the rear support bracket bolts (1) and tighten to the proper specification.

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7. Install the front support bracket bolts (1a) and tighten to the proper specification.
8. Remove the hydraulic lift (1b).
9. Engage the right rear brake lines and close the retaining clips.
10. Engage the rear brake lines and close the retaining clips.
11. Install the toothed washer securing the heat shield to the body.
12. Install the right rear splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE .
13. Connect the vent line quick connect fitting.
14. Connect the fuel return line quick connect fitting.
15. Connect the fuel supply line quick connect fitting
16. Connect the fuel pump wire harness connector.
17. Install the fuel pump and the vent line access covers and securely tighten the screws.
18. Install the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
19. Install the muffler assembly. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
20. Connect the negative battery cable.