Draining the fuel system

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Wendy Warren
5 years ago
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1 1(6) Draining the fuel system Special tools: , , , , Safety See Safety regulations for handling fuel. Engagement Remove the cover on the valve which is positioned on the fuel rail. Connect adapter to fuel draining unit , and Connect the adapter to the valve on the fuel rail in the locked position (figure 1, valve closed). Start the fuel drainage unit. Unlock the adapter (illustration 2 valve open). Raise the car. Draining the fuel system Remove the cover on the valve cap positioned at the fuel filter. Connect venting hose to the valve prior to the fuel filter. It takes approximately 2 minutes to evacuate the system. Installation Draining the fuel tank Special tools: , Reinstall the components in reverse order. Caution! Do not forget to reinstall the valve caps. 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 lead. See Note

2(6) when disconnecting/connecting the battery lead Warning! RISK OF EXPLOSION! THE USE OF A FRESH AIR MASK IS RECOMMENDED. Insert the heavy duty hose 1.

2 2(6) when disconnecting/connecting the battery lead Warning! RISK OF EXPLOSION! THE USE OF A FRESH AIR MASK IS RECOMMENDED. Insert the heavy duty hose 1.3 meters into the fuel filler pipe, measured from the edge of the opening of the filler pipe. Pump until air comes out. (V70) Fold up both sides of the rear seat. (S80, S60) Remove the seat cushion for the rear seat. Remove the right side cushion. See Side cushion Disconnect the connector at the hinge. Remove: the mounting screw for the hinge the screw for the seatbelt end mounting. Release the strap/straps of the folding mechanism for the seat belt buckle. (Hooked into place on the lower edge of the backrest). Lift out the backrest. Fold the carpet (1) out of the way. Remove the insulation panel. Cover the area (2) around the cover and between the doors with absorbent material. Caution! Ensure that there is no risk of dirt getting into the tank. Removing the fuel tank filler cap over the fuel tank units Remove the covers (1.2) over the fuel tank units. Disconnect the fuel tank unit connectors (3). Remove the hoses from the fuel tank unit. Draining the fuel tank

3 3(6) Special tools: Clean the area around the fuel tank unit thoroughly. Open the right fuel tank unit. Insert the heavy duty hose and suck out the remains from the bottom of the righthand side of the fuel tank. Connect hose to the heavy duty hose. Suck out the remains from the bottom of the fuel tank unit reservoir. Carefully remove the overflow pipe from the reservoir. Remove the thin hose ( ) from the heavy duty hose. Connect the thin hose to the overflow pipe. Use a hose clamp. Pump until a lot of air comes out. Open the left fuel tank unit. Insert the heavy duty hose and suck out the remains from the bottom of the lefthand side of the fuel tank. Installation Right fuel tank unit: Place the overflow pipe approximately half a centimetre to the lefthand side Grip the right fuel tank unit reservoir. Pinch the fuel tank unit reservoir so that the float is held in its lowest position Lower the reservoir carefully while rotating it backwards around the frontrear shaft on the float Install the overflow pipe on the reservoir. Left fuel tank unit: Install a new Oring. Lubricate the new Oring using petroleum jelly Press the left fuel tank unit down so that the row of protruding cables runs along the car Check that the Oring is not trapped Tighten the screw. Tighten to 60 Nm Wipe up any fuel spillage Position the wiring in the cutout in the rubber ring. Note! Check that the arrow on the cover is between the markings on the tank. If the arrow is outside the markings the fuel gauge sensor will give an incorrect value and the float may catch

4 4(6) against the inner wall of the tank. If not: Slacken off the screw and adjust the position of the fuel tank unit. Tighten as above. Right fuel tank unit, continued: Install a new Oring. Lubricate the new Oring using petroleum jelly Press the right fuel tank unit down so that the fuel line connectors are pointing forwards and to the right Check that the Oring is not trapped Tighten the screw. Tighten to 60 Nm Install the hoses on the fuel tank unit Wipe up any fuel spillage Position the wiring in the cutout in the rubber ring. Note! Check that the arrow on the cover is between the markings on the tank. If the arrow is outside the markings the fuel gauge sensor will give an incorrect value and the float may catch against the inner wall of the tank. If not: Slacken off the screw and adjust the position of the fuel tank unit. Tighten as above. Install the cover over the fuel tank unit. Tighten the nuts. Connect the wiring and the connectors. Install: Leak detection EVAP the backrest the mounting screw for the hinge. Tighten to 50 Nm the connector for the hinge the seat belt end mounting. Tighten to 48 Nm the side cushion. (V70) Fold the seat cushion forward. (S80, S60) Install the seat cushion. Note! 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. Smoke machine

5(6) The smoke machine generates smoke that is used to detect leaks in the EVAP system. Follow the instructions that are supplied with the smoke machine to use it and to check for leaks.

5 5(6) The smoke machine generates smoke that is used to detect leaks in the EVAP system. Follow the instructions that are supplied with the smoke machine to use it and to check for leaks. Information To be able to check for leaks in the whole EVAPsystem, the connections must be disconnected and the smoke machine must be connected in such a way that the smoke is not stopped by nonreturn valves or by the EVAPpump being closed. Two persons should help each other when checking for leaks. One that operates the smoke machine and one that visually checks for leaks. Hint: To see the smoke easier, use a powerful light with flood lights. The smoke contains a colouring agent that leaves invisible marks in case of leaks. These marks are seen as small green spots when they are illuminated with UVlight and yellow screened glasses are used for viewing. Connecting smoke machine This shows the procedure for a 5cylinder turbo engine. Other engine alternatives have similar EVAPsystems. Disconnect the EVAPpump, located under the inlet manifold in front of the engine in rubber mounting. Press together the lock on the outlet hose (1) and pull it loose. Press aside the lock on the connector (2) and disconnect it. Clamp shut the hose closest to the connection to inlet manifold with locking pliers. The EVAPpump sucks in hydrocarbons through

6(6) the line mounted with quickcoupling (1). The hose (2) receives vacuum since it is connected to the inlet manifold. The nonreturn valve results in gas only being able to flow in to the inlet.

6 6(6) the line mounted with quickcoupling (1). The hose (2) receives vacuum since it is connected to the inlet manifold. The nonreturn valve results in gas only being able to flow in to the inlet. The other hose (3) leads in to the connection before the turbo. Disconnect the hose (4) at the EVAPpump. Connect the smoke machine to the hose that you just disconnected. Fill the hoses with smoke and check that the hoses and nonreturn valves are intact. Check for leaks in plastic hose to carbon canister Insert the smoke machine's tapered nozzle in the line that was installed with quickcoupling in the EVAPpump (1). Lift up the vehicle according to: Jacking points, body. Fill the system with smoke. Check that there are no leaks in the hose to the carbon canister. Note! It is natural that smoke seeps out at the tank pipe. Finishing Install: the hose on the EVAPpump the hose with quickcoupling the connector the EVAPpump with its rubber mount. Note! Make sure that the locks on the quickcoupling and connector are locked securely. Remove the lock grip pliers.

AIR CLEANER GENERAL REMOVAL. 1CAUTION Do not run engine without filter element in place. Debris could be drawn into the engine causing damage.

AIR CLEANER GENERAL REMOVAL. 1CAUTION Do not run engine without filter element in place. Debris could be drawn into the engine causing damage. AIR CLEANER GENERAL The air cleaner prevents foreign material from entering the carburetor and engine by trapping airborne dust and dirt in the filter element. Service air cleaner filter element every