Warning! Gasoline is highly flammable, so special precautions must be taken when working on any component of the fuel system! Do not smoke, and do not approach the work area with an open flame or an uncovered carrier. Do not carry out such work in garages equipped with natural gas heaters (such as water heaters, dryers, etc.)! The work area must be well ventilated. If gasoline comes in contact with your skin, wash it off immediately with soap and water. Wear safety goggles and have a fire extinguisher handy when doing any work on the fuel system. If gasoline spills, immediately wipe up the puddle, but do not keep gasoline-soaked rags in places where there is a risk of ignition!
System check
1. If you smell gasoline while driving or after the car has stood in the sun, you must immediately check the condition of the entire fuel system.
2. Remove the fuel tank cap and inspect it for damage and signs of corrosion. Assess the condition of the sealing element of the cover. Replace defective components.
3. Inspect the fuel supply and return lines for cracks or deformations. Evaluate the tightness of the fittings on the fuel distribution line and the built-in fuel filter.
Attention! Be sure to depressurize the fuel system before servicing fuel system components (see chapter Power supply and exhaust systems)!
4. In order to provide access to some components of the power system, such as the fuel tank and separate fuel lines laid under the bottom, the car must first be hung above the ground (see the relevant Section in Administered).
5. After hanging the car, inspect the fuel tank and its filler neck for holes, cracks and other damage. Particular attention should be paid to the state of articulation of the neck with the tank. Sometimes fuel leaks occur due to loose neck clamps, or due to aging of the rubber from which the neck is made. Carefully examine the condition of the fuel tank mounting elements, if necessary, make the appropriate corrections.
Attention! Never attempt to repair the fuel tank yourself (excluding the replacement of its rubber components), - remember that the contact of the fuel vapors contained in the tank with the open fire of a gas burner inevitably leads to the ignition of the latter!
6. Carefully check up reliability of a tightening of all union connections of fuel hoses and the metal lines coming from a tank. Check for deformation or signs of aging in flexible hose materials. Replace defective components.
Filter replacement
Petrol models
Fuel filter installation details on petrol models
1. Open the fuel tank cap to equalize the pressure in it with atmospheric pressure.
2. Using a special clip, pinch the fuel hoses.
3. Turn out a hollow bolt of union connection (6).
4. Loosen the fixing screws (2).
5. Remove assembly from support rubber pads (7) and release from the collar (3) fuel filter (5).
6. Disconnect the fuel inlet line from the old filter (1) and, replacing the sealing ring, connect it to a new filter.
7. When installing a new filter, make sure that the plastic sleeve protrudes from both sides of the clamp (3), - otherwise the risk of galvanic corrosion increases.
Note. The arrow on the filter housing must point in the direction of fuel flow.
8. Further installation is carried out in the reverse order to the dismantling of the components.
9. Finally, start the engine and check the relevant components of the fuel path for signs of leaks, tighten the fasteners if necessary.
Diesel models - replacement of filters, removal of moisture and air
G270 CDI Full Flow Fuel Filter (M612)
Details of installing a full-flow fuel filter on diesel models equipped with an M612 engine (G270 CDI):
1. Remove panels of finishing of a head of cylinders.
2. Disconnect from the fuel filter (3) inlet (1) and graduation (2) fuel lines, - prepare replaceable mounting clamps.
3. If the filter will be removed together with the mounting clamp (6), loosen the bolts (4) and slightly raise the fuel cooler (5).
4. Loosen the clamping screw of the mounting clamp (6) and remove the fuel filter (70), or - if required - loosen the appropriate fasteners and remove the filter assembly with the clamp.
5. Installation is carried out in the reverse order - before starting the engine, the filter must be filled with fuel, and the low-pressure fuel path must be purged (see Section Bleeding air from the low pressure circuit of the fuel path).
6. Finally, start the engine and check the fuel system for signs of leaks. Make appropriate corrections if necessary.
G400 CDI Full Flow Fuel Filter (M628)
Details of installing a full-flow fuel filter on diesel models equipped with an M628 engine (G400 CDI):
1. Open the hood and lock it in an upright position.
2. Remove the air cleaner assembly (1) (see chapter Power supply and exhaust systems).
3. Disconnect from the fuel filter (70) inlet (70/1) and graduation (70/2) fuel lines, - prepare replaceable mounting clamps.
4. Loosen the clamping screw of the mounting clamp (3) and remove the fuel filter (70), or - if required - unscrew the bolts (2) and remove the filter assembly with the collar.
5. Installation is carried out in the reverse order.
6. Finally, start the engine and check the fuel system for signs of leaks. Make appropriate corrections if necessary.
Fuel pre-filter with sump - sediment removal and filter element replacement
Attention! The fuel pre-filter must be replaced at the same time as the full-flow filter (see above)!
Details of installation of the preliminary fuel filter (diesel models)
Fuel pre-filter design (diesel models)
1. Replace full flow fuel filter (see above).
2. Turn out fixing bolts and remove a protective screen (1).
3. Pull on the drain valve (2) hose with a diameter of about 8 mm.
4. Loosen the drain valve (2) and pour the water-fuel mixture into the prepared container.
5. Disconnect the connector (3).
6. Unscrew the cover (4) separator, - prepare a replacement sealing ring.
7. Remove from cover (4) filter element (5).
8. Installation is carried out in the reverse order.
9. On models equipped with a 612 series engine, be sure to finally purge the low pressure fuel line (see chapter Power supply and exhaust systems).
Air removal
1. If the engine has stopped due to the complete emptying of the fuel tank, then after refueling it is necessary to remove air from the fuel system. To do this, start the engine for no more than 60 seconds without interruption until it starts to run stably.