Removal
FUEL TANK - ADVANCED EVAPSWARNING: Ensure fuel handling precautions are strictly adhered to when carrying out following instructions.
CAUTION: Before disconnecting any part of fuel system, it imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system.
Remove
1. Disconnect battery ground lead.
2. Drain fuel tank completely.
3. Remove 6 screws securing tail door tread strip and remove tread strip.
4. Remove RH luggage compartment side panel.
5. Fold back loadspace carpet and sound insulation to reveal access panel.
6. Remove 6 screws securing fuel pump access panel.
7. Remove access panel.
8. Disconnect multiplugs from fuel pump and pressure sensor
9. Noting their fitted positions, disconnect both fuel connections by pressing the black release latches on each connector and pushing the connector back down the line.
10. Care must be taken to catch any excess fuel which may spill from the fuel lines once removed.
11. Raise rear of vehicle.
WARNING: Support on safety stands.
12. Mark location of anti-roll [sway] bar straps.
13. Remove nuts and bolts securing anti-roll [sway] bar straps, and allow bar to swing down clear of tank.
14. Disconnect pressure sensor breather pipe connection.
15. Disconnect vent line quickfit connector from liquid/vapor separator.
16. Remove torque screw cap from hose to tank filler neck clip.
17. Loosen clip screw securing hose to tank filler neck.
18. Release hose from filler neck and internal filler neck breather hose from fuel tank.
19. Remove and discard fuel filler neck clip.
20. Remove nut and bolt securing RH side of upper fuel tank strap to chassis.
21. Remove 4 nuts and bolts securing fuel tank cradle.
22. Remove fuel tank cradle.
23. With assistance tilt right hand side of tank upwards and manoeuvre through chassis to remove.
Note: Do not carry out further dismantling if component is removed for access only.
24. Release vent hose from tank pressure sensor.
25. Remove vent hose from 3 fuel tank clips.
26. Using service tool LRT-19-009 loosen and remove the metal locking ring.
27. Pry the pump from the tank opening using a blunt instrument under the edge of the lip of the pump flange.
CAUTION: Do not lift the pump from the tank using the feed and return stubs.
28. Remove and discard seal.
Refit
29. Fit NEW pump seal to tank opening.
30. Carefully lower pump into tank opening, pressing firmly on the pump top flange to allow correct positioning.
NOTE: Ensure location tag on pump top flange is engaged correctly to tank opening lip.
31. Fit locking ring and tighten to 35 Nm using service tool LRT-19-009.
32. Fit vent hose to fuel tank clips and connect to pressure sensor.
33. With assistance, fit fuel tank into position.
34. Fit fuel tank cradle and secure with nuts and bolts.
35. Align upper fuel tank strap and secure with nut and bolt.
36. Fit NEW clip to fuel filler neck hose.
37. Connect fuel filler neck internal breather to tank.
38. Connect fuel filler neck hose to tank.
39. Position fuel filler neck hose clip and tighten until head shears.
40. Connect vent line quickfit connector to liquid/vapor separator.
41. Connect vent line hose connection.
42. Position anti-roll [sway] bar straps and secure with nuts and bolts.
43. Remove stand(s) and lower vehicle.
44. Connect both fuel lines to the pump by pushing the connectors down each line square to the pump connection until the connectors positively latches.
45. Connect multiplugs to fuel pump and pressure sensor.
46. Connect battery earth lead.
47. Refill tank with drained fuel.
48. Run the engine to check for any fuel leaks.
49. Fit access panel and secure with screws.
50. Reposition loadspace sound insulation and carpet.
51. Fit RH luggage compartment side panel.
52. Fit tail door tread strip and secure with screws.