Fuel Tank Removal and Installation

19.55.01 Tank - Fuel

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.

Remove
1. Disconnect battery earth lead.
2. Drain fuel tank.

WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.





3. Remove 4 nuts and remove fuel tank RH access cover.





4. Disconnect multiplug from fuel pump.
5. Remove centre console.





6. Release cable securing clip from handbrake compensator, release handbrake cables from compensator and remove securing clip.
7. Remove rear propeller shaft.
8. Withdraw handbrake cables from body and move aside for access.
9. Remove RH rear wheel arch liner.





10. Release clip from breather hose and disconnect breather hose from filler neck.

WARNING: Fuel vapour is highly flammable and in confined spaces is also explosive and toxic. Always have a fire extinguisher containing foam, CO2, gas or powder close at hand when handling or draining fuel.





11. Release fuel tank breather and charcoal canister vent pipes from clip on filler neck.
12. Remove clip from breather hose and vent pipe.





13. Remove 16 bolts and 4 nuts securing fuel tank shields.





14. Disconnect 3 pipes from charcoal canister, remove 2 Torx bolts and remove charcoal canister.





15. Loosen 4 bolts securing rear sub-frame to allow removal of tank shields.
16. Collect fuel tank shields.





17. Disconnect fuel tank filler hose from fuel tank filler neck.





18. Remove 2 screws securing fuel filter and release fuel filter from mounting brackets.
19. Position container to catch fuel spillage.





20. Disconnect 3 fuel hoses and 1 reference pipe, remove fuel filter.

WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.

21. Remove container.





22. With assistance remove 5 bolts securing fuel tank to body, lower and remove tank.

NOTE:
^ Pull vent and breather hoses through body while lowering fuel tank.
^ Do not carry out further dismantling if component is removed for access only.





23. Release fuel tank breather hose and charcoal canister vent pipe from securing clips on fuel tank.





24. Release 2 clips and disconnect 2 hoses from fuel tank. Remove 2 scrivets and remove vapour separator.
25. Remove charcoal canister to charcoal canister purge solenoid feed pipe from fuel tank.
26. Remove 4 scrivets securing straps to fuel tank. Collect straps.

Refit
1. Position straps to fuel tank and secure with scrivets.
2. Fit charcoal canister to charcoal canister purge solenoid feed pipe to fuel tank.
3. Fit vapour separator to fuel tank and secure with 2 scrivets, connect 2 hoses to fuel tank and secure with clips.
4. Fit fuel tank breather pipes and charcoal canister vent pipes to clip on fuel tank filler neck.
5. Position tank assembly and breather pipes to vehicle.
6. With assistance, fit bolts securing fuel tank to body and tighten to 45 Nm (33 lbf.ft).

NOTE: Pass vent and breather hoses through body while fitting tank.

7. Connect fuel hoses to fuel filter.
8. Position fuel filter to mounting brackets and secure with screws.
9. Fit fuel tank shields, but do not fit nuts and bolts.
10. Connect breather hose to filler neck, fit and secure clip.
11. Position fuel tank vent pipe to filler neck.
12. Connect fuel tank filler hose to fuel tank filler neck.
13. Tighten bolts securing subframe to body to 165 Nm (129 lbf.ft).
14. Fit charcoal canister, tighten 2 bolts and connect 3 pipes to charcoal canister.
15. Fit bolts and nuts securing fuel tank shields and tighten to 25 Nm (18 lbf.ft).
16. Fit fuel tank breather hose to fuel tank filler neck and secure with clip.
17. Fit fuel tank breather pipes and charcoal canister vent pipes to clip on fuel tank filler neck.
18. Fit securing clip to fuel tank breather hose and charcoal canister vent pipe.
19. Fit RH rear wheel arch liner.
20. Insert handbrake cables through body.
21. Fit rear propeller shaft.
22. Fit handbrake cable retaining clip.
23. Fit handbrake cables to compensator.
24. Fit cable retaining clip to handbrake compensator.
25. Fit centre console.
26. Connect multiplug to fuel pump.
27. Fit RH fuel tank access cover and secure with 4 nuts.
28. Fill fuel tank with extracted fuel.
29. Connect battery earth lead.