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Fuel lines tank - engine bay

Fuel lines tank - engine bay

Warning

Removal of the fuel filter involves partial dismantling of the car's fuel system. The following points must therefore be observed in connection with this work:

• Make sure a class BE fire extinguisher is close to hand! Consider the risk of sparking, e.g. when breaking circuits, short-circuits etc.

• Absolutely No Smoking!

• Ensure that there is a good exchange of air. If approved ventilation for the extraction of fuel fumes is available, this should be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


Important

Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.


To remove


1. Petrol engine: Reduce the fuel pressure by removing fuse 2 while the engine is running (fuse 2 is located in the main fuse box in front of the battery). Once the engine has stopped, turn the ignition key to LOCK and refit the fuse.


2. Disconnect the negative battery cable.

3. Z19: Remove the upper engine cover. Remove the panel guard. Press out the clips' centre pin from the wheel housing side.

B284: Remove the upper engine cover and the upper turbocharger delivery pipe.

B207 RHD: Remove the air cleaner assembly.

B207 with ethanol sensor: Remove the fuel line from the Ethanol sensor .

4. Disconnect the fuel lines in the engine compartment using 83 95 261 Fuel line tool and plug the lines. Use 82 92 948 Plugs, A/C system, kit . (B284 has a delivery line only)


5. Raise the car.

6. CV: Remove Chassis reinforcement, front subframe, CV, Z19DTH/DTR, A20NFT/LHU

7. Z19: Remove Exhaust pipe, front . B207, B284: Remove the exhaust pipe flange and unload the flexible section using 83 95 212 Strap .

8. Detach the steering shaft joint from the steering gear.


9. Remove the rear torque rod bolt.


10. B284 RHD: Place a receptacle under the car and detach the power steering lines from the steering gear.


11. Use a column jack to relieve the load on the subframe and remove the rear bolts and stays.


12. Lower the rear edge of the subframe.

13. Undo the fuel lines from their holders and the brake pipes from the front holders.


Important

Be careful that the brake pipes do not get damaged.


14. Place a receptacle under the car, detach the fuel lines at the fuel tank and plug them. For diesel and EU tank, use 83 95 261 Fuel line tool .


15. Lower the pipes.


To fit


1. Fit the fuel lines in their holders.


2. Connect the fuel lines to the tank.


3. Raise the subframe using 83 95 311 Trolley lift with 83 94 801 Parent fixture and 83 96 137 Centring tool, subframe - body . Align the tool to the guide holes in the body. Fit the stays and the bolts.

Tightening torque, subframe: 75 Nm + 135° (55 lbf ft +135°)

Tightening torque, stay: 90 Nm + 45° (67 lbf ft + 45°)


4. Fit the torque rod bolt.

Tightening torque 80 Nm (59 lbf ft).


5. Fit the steering shaft joint onto the steering gear. Clean the threads and apply Thread locking adhesive, Loctite 242 to the threads.

Tightening torque 30 Nm (22 lbf ft)


Warning

Check that the bolt fits into the groove on the pinion shaft.


6. B284, RHD: Fit the power steering lines to the steering gear. Use new O-rings.

Tightening torque 12 Nm (9 lbf ft)


7. Fit the exhaust pipe flange and exhaust pipe mountings.

Tightening torque 30 Nm (22 lbf ft)

Z19: Fit Front exhaust pipe .

8. CV: Fit Chassis reinforcement, front subframe, CV, Z19DTH/DTR, A20NFT/LHU

9. Lower the car.

10. Connect the fuel lines in the engine bay (B284 only as a delivery line).


11. B207 RHD: Fit the air cleaner assembly.

Z19: Fit the panel guard over the fuel lines and the upper engine cover.

B207 with ethanol sensor: Fit the fuel line to the Ethanol sensor .

12. Reconnect the negative battery cable.

13. Carry out Procedures after reconnecting the battery .