Removal and Replacement
Fuel Tank
This is a "Trustmark Authoring Standards (TAS) Repair Procedure"
- TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips.
- TAS removal and installation procedures use a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component.
- Many of the TAS procedures will have the installation information within the removal steps.
- The TAS color illustrations use a variety of symbols to indicate important details of the procedures. It is important to understand these symbols in order to properly used the TAS procedures.
Refer to How to Use TAS Procedures and TAS Symbol Glossary at Vehicle | Description and Operation for additional information on these TAS procedures.
For additional information, refer to How to Use TAS Procedures
Removal
WARNING: Fuel may still be present in the fuel tank after draining.
WARNING: Avoid flames, sparks or lighted substances.
CAUTION: Extreme cleanliness must be exercised when handling these components.
CAUTION: Make sure that all openings are sealed. Use new blanking caps.
NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.
All vehicles
1 Disconnect the battery ground cable.
For additional information, refer to Specifications [1][2]Specifications
2 Drain the fuel tank.
For additional information, refer to Fuel Tank Draining Procedures
3 Remove the coin tray.
4 Release the adjusting nut and disconnect the parking brake cables from the compensator.
5 Fold the RH rear seat cushion forwards.
6 Release the
carpet and remove the grommet.
Vehicles with fuel fired heater
CAUTION: Extreme cleanliness must be exercised when handling these components.
CAUTION: Make sure that all openings are sealed. Use new blanking caps.
All vehicles
7 Disconnect the electrical connector and the breather hose.
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
8 Raise and support the vehicle.
9 Remove the exhaust system.
For additional information, refer to Exhaust System Service and Repair
WARNING: Do not lever the driveshaft joints to release from the power transfer unit or the rear differential flanges.
CAUTION: Make sure that the driveshaft is supported with suitable retaining straps.
CAUTION: Make sure that new bolts are installed.
Torque to: 40 Nm
NOTE:
All vehicles built up to VIN 180237
Torque to: 25 Nm
NOTE:
All vehicles.
NOTE:
This step requires the aid of another technician.
Torque to: 25 Nm
CAUTION: Make sure that the centre driveshaft joint is compressed. Failure to follow this instruction may result in damage to the component.
CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.
NOTE:
This step requires the aid of another technician.
Compress the propshaft centre joint.
Tie the propshaft to the right hand side of the vehicle.
NOTE:
Si6 built from VIN 180238
Torque to: 25 Nm
10 Release the parking brake cables from the fuel tank cradle.
11 Remove the fuel line cover.
CAUTION: Extreme cleanliness must be exercised when handling these components.
CAUTION: Make sure that all openings are sealed. Use new blanking caps.
12 Disconnect the 2 fuel lines.
Vehicles with fuel fired heater
CAUTION: Extreme cleanliness must be exercised when handling these components.
CAUTION: Make sure that all openings are sealed. Use new blanking caps.
All vehicles
WARNING: This step requires the aid of another technician.
CAUTION: Make sure that new bolts are installed.
13 Remove the fuel tank.
E70 - Powertrain Jack
Torque to: 25 Nm
NOTE:
Do not disassemble further if the component is removed for access only.
14 Remove the fuel tank pad.
CAUTION: Extreme cleanliness must be exercised when handling these components.
Remove the fuel pump module locking ring.
Special Service Tool
Locking Ring, Fuel Tank, 310-123
Torque to: 200 Nm
CAUTION: A new O-ring seal is to be installed.
15 Release the fuel filter.
NOTE:
Petrol illustration shown, diesel similar.
16 Remove the fuel filter.
NOTE:
Petrol illustration shown, diesel similar.
17 Remove the fuel pump module.
Push down to release the fuel sender from clip.
Slide fuel sender assembly forward to release from the bracket.
Manoeuvre fuel sender out of the tank.
18 Remove the fuel tank cradle.
Installation
1 To install, reverse the removal procedure.
2 Refill the fuel tank.
3 Adjust the parking brake.
For additional information, refer to Parking Brake Cable Adjustment Adjustments