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4. CAUTION: Make sure t hat t he fuel pump and sender unit filt erremains locat ed behind the lip of the fuel pump and sender unit pri or t oinst allat ion.
• NOTE: Not e the orient ation of t he component prior t o remova l.
Releas e the locking tangs and remove the filt er from t he fuel pump andsender unit.
4.
Installation
1. CAUTION: Ins ta ll the magnet from t he s ervice kit . If the magnethas alrea dy been ins ta lled, check t he magne t for foreign mat erial andremove a s necessary.
1.
2. CAUTIONS:
Make sure t hat al l component s are inst alled fully home t o the fuel pump andse nder unit .
Make sure t hat t he components a re i nst alled t o the note d posit ion in t he removalst eps .
To ins ta ll, reverse t he remova l procedure .
2.
Page 1578 of 3229
Publ is hed: 24-Oct -2011
Fuel Tank and Lines - I6 3.2L Petrol - Fuel Pump and Sender Unit Filter
Magnet
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Refer t o: Fuel Pump and Sender Uni t (310-01A Fuel Tank and Li nes -I6 3.2L Pet rol, Removal and Ins t al lat ion).1.
2.
Installation
1. CAUTION: Make s ure that the component is i nst all ed full yhome t o t he fuel pump and s ender uni t.
To i nst all , revers e t he removal procedure.
1.
Page 1579 of 3229
Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel -
C apacitiesItemCapacity (liters/gallons)
Fuel t ank68.0/14.9
General Specification
ItemSpecification
Fuel del ivery modulePAG ModuleLocat ionin the RH si de of the tank
Maximum output @12.5 vol ts160l /hr
Operat ing press ure0.2 BarFuel t ank s ender unit sMAgnet ic Pas s ive Pos it ion Sensor (MAPPS)
Torque Specifications
DescriptionNmlb-ft
Degas nipple1511Fuel fil ter brackets2518
Fuel fil ter cover nut s97
Fuel fil ter t o ret aini ng bracket bolt97Fuel press ure pipe t o block107
Fuel pump bol ts2216
Fuel t ank bolt s*2518Fuel t ank fi ll er pi pe bracket s107
* New nuts/bolts must be fitted
Page 1580 of 3229
Publi s hed: 11-May-2011
Fuel Tank and Lines - TD4 2.2L Diesel - Fuel Tank and Lines
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Fuel tank fill er cap and lanyard
2-Fuel tank fill er pipe
3-Fuel tank s upport cradle4-Fuel tank
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5-Exhaus t heat s hi eld
6-Fuel line underfloor prot ect ion t ray
7-Fuel ret urn l ine8-Fuel fi lt er as s embly
9-Fuel temperat ure sens or
10-Fuel supply line11-Fuel del ivery modul e
12-Hos e - fuel t ank breather
OVERVIEW
The TD4 dies el fuel s ys t em i ncorporat es a l ow and hi gh-pres sure (HP) ci rcuit t o provide the engine wit h s uffi cient fuel forall operat ing condi ti ons . The l ow-pres s ure (LP) sys tem compri ses :
Molded pl as t ic s addle-t ype fuel t ankFuel deli very module (wi th integral i n-t ank pump)Fuel l evel s ens orsFuel s upply and return li nesFuel fil ter as sembl y.
• NOTE: Fuel i s drawn from t he fuel t ank by the engine mount ed li ft pump. The i n-t ank pump does not deli ver fuel t o t heengi ne, and onl y delivers fuel through the 2 jet pumps t o maint ain fuel in t he fuel deli very pot.
The HP s ys tem features a Bos ch Generati on 3 common rail inject ion s ys tem.For addit ional informat ion, refer t o: Fuel Chargi ng and Cont rol s (303-04B Fuel Charging and Cont rols - TD4 2.2L Di esel ,Des cript ion and Operat ion).
FUEL TANK CONSTRUCTION
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The fuel t ank has a useable capaci ty of 68.0 li ters (18.0 US gal lons) and i s des igned wit h a run dry s trat egy t o prevent ai rentering t he HP fuel s ys tem. The t ank is formed from a 6-layer lami nat ed blow-molded pl as t ic t o provi de high mechani cals trengt h and complet e emis s ions i ntegri ty. The t ank is a sealed uni t wit h i nt ernal acces s being via the fuel del iverymodule apert ure locat ed on t he Right -Hand (RH) s ide of t he tank.
The fuel t ank is l ocat ed cent rall y below the rear s eat posi ti on and is formed to s traddl e the drives haft and exhaus ts ys t em.
A mount ing cradl e and 6 bolt s s ecure t he fuel tank t o t he vehi cle. W hen t he cradle is at tached to the chass i s, t he t ank isposi ti vel y s ecured via foam pads t hat bear agai nst t he underfl oor. The cradle is manufact ured from st eel and incorporateslarge diamet er s t eel t ubing t o prot ect t he fuel t ank leading edge from underbody damage. The cradle al so provides thelocati on for t he parking brake cable bracket s .
A s addle s haped heat s hiel d is at t ached t o t he cradle t o prot ect the fuel t ank from exhaust s ys tem temperature.
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FUEL TANK INTERNAL COMPONENTS
ItemPart NumberDescription1-Fuel tank breat her valve
2-Cross over t ube
3-Coars e fil ter4-Fuel sender uni t fl oat (2 off)
5-MAgneti c Pass i ve Pos it ion Sens or (MAPPS) fuel s ender unit (2 off)
6-Fuel tank breat her hos e7-Fuel del ivery modul e
The fuel t ank compris es the foll owing i nternal component s:
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Int ernal mounti ng bracketFuel deli very module and cross over tube2 MAPPS t ype fuel s ender unit sBreat her valve.
Internal Mounting Bracket
The int ernal mount ing bracket i s molded i nto t he t ank cas ing and provi des the locat ion for the breather val ve, andcros sover tube as s embly.
Fuel Delivery Module
ItemPart NumberDescription
1-In-t ank pump supply to jet pump
2-Fuel s upply t o engine fuel fil ter3-In-t ank pump
4-In-t ank pump supply to jet pump
5-Jet pump (us able s ide of t ank)6-Inl et from us able s ide of t ank
7-Return fuel from engi ne fuel fi lt er
8-Cros s over t ube (from unus able si de of tank)9-Jet pump (unus abl e s ide of t ank)
The fuel deli very module i s located in t he RH s i de of the t ank, and i s s ecured to the bot tom of the t ank wit h a weldedbayonet-t ype lock ri ng. The t op flange of the fuel del ivery module ass embly provides t he int ernal and ext ernal interface fort he tank elect rical and fuel connecti ons . The flange is formed wit h a 6-pin ext ernal el ect ri cal connector t hat is connect ed tot he 2 MAPPS fuel l evel s ens ors , and t he in-tank pump.