Fuel Tank: Service and Repair

FUEL TANK

RENEW





WARNING: This operation results in fuel and fuel vapor being present which is extremely flammable, great care must be taken when work is being carried out on the fuel system and the following precautions must be strictly adhered to:

Smoking must not be allowed near the area: "No Smoking" warning signs must be posted

Around the area: a C02 fire extinguisher must be close at hand: dry sand must be available to soak up any spillage: ensure the fuel is emptied from the tank using suitable fireproof equipment: fuel must not be emptied into a pit: the working area must be well ventilated: ensure the fuel is emptied into an authorized explosion proof container:

The discarded tank must not be disposed of until it is rendered safe from explosion:

Remove the luggage compartment RH side panel. Remove the pump relay from its bracket and remove the relay from the multi-plug connector.

Crank the engine to depressurize the fuel system. Disconnect and remove the battery.

Remove the spare wheel cover and the spare wheel. Empty the fuel tank into a explosion proof container using suitable fireproof equipment.

Clamp the fuel return hose and disconnect the union nut at the fuel tank (1).

Release the hose clip securing the expansion tank supply hose to pipe and disconnect the hose (2). Release the union nut securing the expansion tank return pipe to the fuel tank (3).

Release the three hose clips securing the vent hoses to the fuel tank vent pipes.

Note the position of and disconnect the hoses (4). Note the position of and disconnect the electrical connectors from the fuel gauge tank unit (5). Release the hose clips securing the fuel filler assembly to the body and remove the fuel filler assembly (6).

Remove the two bolts and release the fuel tank securing straps (7).

Remove the LH and RH luggage compartment trim pads.

Remove the seven screws, plain washers and four fibre washers securing the LH side luggage compartment side panel to body lower panel.

Remove the seven screws, plain washers and four fibre washers securing the RH side luggage compartment side panel to body, disconnect the earth leads from the relay bracket and lower the panel. Remove the expansion tank supply pipe (8) Remove the fuel tank.

Remove the fuel gauge tank unit (9).

On fitting a new fuel tank reverse the above procedures ensuring that all earth and electrical connections are secure, also check for fuel leaks.