Removing and installing/replacing the delivery unit (51 l gasoline) (Cooper)
Special tools required:
- 2 452 189
- 2 445 958
- 33 5 070
Recycling
Fuel leakages when fuel lines are detached. Have a suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.
Attention!
Ensure that the workplace is adequately ventilated!
Avoid skin contact (wear gloves)!
Ensure absolute cleanliness when performing repair work on the open fuel system. Dirt contamination in the fuel tank may impair driving or may even result in vehicle breakdown.
Preliminary work needed:
- Remove REAR SEAT .
Removal:
Release plastic nuts (1) and remove service cap (2).
Unfasten plug connection (1) and disconnect.
Attention!
To unlock/lock or disconnect/connect the fuel line with a quick connector, no tool must be used.
To unlock snap fastener (1) on the fuel line, follow the instructions given below.
Press in locks (1) and (2) in the arrow direction.
Disconnect fuel lines (1) and (2) in the arrow direction.
Press the snap fastener towards the delivery unit. Then press locks (1) and (2) in the arrow direction and detach the snap fastener in the arrow direction.
Set special tools 2 452 189 or 2 445 958 (1) on locking ring (2) from above.
Connect special tool 33 5 070 to the 1/2" reversible ratchet head (3) and set it on special tool 2 452 189 or 2 445 958.
Release locking ring (2) in counterclockwise direction.
Remove delivery unit (1) from the fuel tank in the arrow direction.
Installation:
Attention!
Replace seal (1) after each disassembly of the delivery unit.
Replace gasket (1).
Parts : Gasket
Mount gasket (1).
Install delivery unit (1) in the fuel tank in the arrow direction.
Position special tools 2 452 189 or 2 445 958 (1) on locking ring (2) from above.
Connect special tool 33 5 070 to the 1/2" reversible ratchet head (3) and set it on special tool 2 452 189 or 2 445 958.
Tighten locking ring (2) in clockwise direction.
Attention!
Make sure that detent of locking ring for fuel tank is correctly engaged!
Attention!
To unlock/lock or disconnect/connect the fuel line with a quick connector, no tool must be used.
Procedure for installing a new fuel line:
When installing a new fuel line, ensure that lock (1) protrudes.
Insert fuel line (2) into fuel line (1).
Slide fuel line (2) into fuel line (1) by clicking the first lock (white).
Lock the red lock (1) in the arrow direction.
Lock (1) can be locked only if the fuel lines are connected correctly.
Check to ensure that snap fastener (1) locks in place correctly.
The snap fastener must engage audibly and perceptibly.
A traction check is not permitted!
Procedure for installing a previous fuel line:
When installing a fuel line that has already been installed, the red lock (1) is already pressed down.
Slide fuel line (2) into fuel line (1) in the arrow direction until the two locks lock audibly.
Check to ensure that snap fastener (1) locks in place correctly.
The snap fastener must engage audibly and perceptibly.
A traction check is not permitted!
Locking tabs (1) and (2) must be locked in place.
Mount and lock the snap fastener.
Attention!
Check the locking mechanisms of the snap fastener for damages and replace if necessary!
The snap fastener must engage audibly and perceptibly.
Check to ensure that the snap fastener locks in place correctly.
A traction check is not permitted!
Connect and lock the connector (1).
Check seal (2) for damage and, if necessary, replace it.
Fit service cap (2) and position and tighten plastic nuts (1).
Required follow-up work:
- Install REAR SEAT .