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Home › Fiat › 2021 › 500X Pop › Repair and Diagnosis › Engine Mechanical › Fuel System › Fuel Delivery › Tank, Fuel › Removal And Installation

Removal And Installation

REMOVAL 

  1. Perform the fuel pressure release procedure. Refer to FUEL DELIVERY, STANDARD PROCEDURE .
  2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  3. Remove the muffler assembly. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
  4. Remove the propeller shaft assembly on AWD equipped vehicles .
  5. Remove the right side belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY PAN, SIDE, REMOVAL AND INSTALLATION .
  6. Remove the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
    GC0164830Courtesy of CHRYSLER GROUP, LLC
  7. Lift the cover, remove the screws and the access cover to the fuel pump (1).
    GC0162995Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect the wire harness connector (1) from the electric pump fuel.
  9. Disconnect the fuel vapor quick connect couplings (3).
  10. Disconnect the quick coupling of the fuel delivery pipe (2).
    GC0163056Courtesy of CHRYSLER GROUP, LLC
  11. Loosen the clamp and remove the hose from the fuel fill tube (1).
    GC0163023Courtesy of CHRYSLER GROUP, LLC
  12. Disengage the fuel vapor hose from the retaining clips (1).
    GC0164517Courtesy of CHRYSLER GROUP, LLC
  13. Remove the toothed washer (1) securing the heat shield to the body.
    GC0163143Courtesy of CHRYSLER GROUP, LLC
  14. Open the retaining clips and disengage the rear brake lines (1).
    GC0163140Courtesy of CHRYSLER GROUP, LLC
  15. Open the clips and release the right rear brake line (1).
    GC0165348Courtesy of CHRYSLER GROUP, LLC
  16. Place a suitable hydraulic lift (1a) under the tank and remove the front bolts (1b) securing the mounting brackets.
    GC0162992Courtesy of CHRYSLER GROUP, LLC
  17. Remove the rear fuel tank support bracket bolts (1).
  18. Disconnect the quick coupling of the vapor hose from the fuel tank to the canister.
    GC0165981Courtesy of CHRYSLER GROUP, LLC
  19. Lower the tank and unhook the fuel delivery pipe from the retaining clips (1).
    GC0165305Courtesy of CHRYSLER GROUP, LLC
  20. Lower the support and remove the fuel tank (1).
    GC0163136Courtesy of CHRYSLER GROUP, LLC
  21. Install the 2000002100 (EMEA) or (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (NAFTA) tool (1a) and remove the lock nut from the fuel pump assembly (1b).
    GC0165293Courtesy of CHRYSLER GROUP, LLC
  22. Raise the fuel pump assembly.
  23. Disconnect the quick coupling of the fuel vapor recovery pipe (1).
    GC0165245Courtesy of CHRYSLER GROUP, LLC
  24. Remove the fuel pump assembly (1).
    GC0166103Courtesy of CHRYSLER GROUP, LLC
  25. Remove the seal ring from the tank (1).

INSTALLATION 

  1. Install a new seal on the tank.
    GC0163996Courtesy of CHRYSLER GROUP, LLC
  2. Install the fuel pump assembly, taking care to match the references (1a), (1b) and (1c) indicated in the figure.
  3. Tighten the fuel pump assembly lock nut.
  4. Using the hydraulic lift, put the fuel tank into position.
  5. Engage the fuel delivery pipe with the retaining clips.
  6. Connect the quick coupling of the vapor hose from the fuel tank to the canister.
    GC0163072Courtesy of CHRYSLER GROUP, LLC
  7. Install the rear support bracket bolts (1) and tighten to the proper torque specifications. Refer to FUEL DELIVERY, TECHNICAL SPECIFICATIONS .
    GC0165796Courtesy of CHRYSLER GROUP, LLC
  8. Install the front support bracket bolts (1a) and tighten to the proper torque specifications. Refer to FUEL DELIVERY, TECHNICAL SPECIFICATIONS .
  9. Remove the hydraulic lift (1b).
  10. Engage the right rear brake lines and close the retaining clips.
  11. Engage the rear brake lines and close the retaining clips.
  12. Install the toothed washer securing the heat shield to the body.
  13. Engage the fuel vapor hose with the retaining clips.
  14. Connect the hose to the fuel fill tube and tighten the clamp.
  15. Connect the quick coupling of the vapor pipe.
  16. Connect the quick coupling of the fuel delivery pipe.
  17. Connect the wire harness connector to the electric fuel pump.
  18. Install the access covers for the fuel pump and securely tighten the screws.
  19. Install the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
  20. Install the right side belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY PAN, SIDE, REMOVAL AND INSTALLATION .
  21. Install the propeller shaft assembly .
  22. Install the muffler assembly. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
  23. Remove the support and lower the vehicle.
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