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 How to Use TAS Procedures

Removal

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.

WARNING: After the fuel tank drain is complete always fit the sealing covers over the drain ports. Failure to do so will mean that fuel vapor can escape.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

CAUTION: Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

NOTE:
Removal steps in this procedure may contain installation details.
For additional information, refer to Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions Petrol and Petrol-Ethanol Fuel Systems Health and Safety Precautions
1 Disconnect the battery ground cable.
For additional information, refer to Specifications Battery, Mounting and Cables

WARNING: Make sure to support the vehicle with axle stands.
2 Raise and support the vehicle.
For additional information, refer to Fuel Tank Draining Fuel Tank Draining

Bolts: 6 Nm
Nuts: 3 Nm

CAUTION: Discard the retaining clip.
3 Remove the tamper proof cover.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

CAUTION: Be prepared to collect escaping fluids.

CAUTION: Make sure that all openings are sealed. Use new blanking caps.

NOTE:
Transmission support heat shield shown removed for clarity.

WARNING: Secure the component to the transmission jack.

CAUTION: Do not lower the fuel tank more than 250 mm.

NOTE:
Note the orientation of the two rear retaining bolts and washers.
4 Using a suitable transmission jack, lower the fuel tank sufficiently only to access the top of the fuel tank.
E21 - Transmission jack

Torque to: 45 Nm

CAUTION: Position the breather and vent hoses through the vehicle body during the fuel tank removal.

NOTE:
Do not disassemble further if the component is removed for access only.
5 With assistance, remove the fuel tank.

NOTE:
Note the position of the locating tang.

Special Service Tool

Locking Ring, Fuel Tank, 310-123

CAUTION: Be prepared to collect escaping fluids.

NOTE:
Remove and discard the O-ring seal.

CAUTION: Take extra care not to damage the fuel tank level sensor float and arm.

NOTE:
Some variation in the illustrations may occur, but the essential information is always correct.

CAUTION: Take extra care not to damage the fuel tank level sensor float and arm.

Installation

NOTE:
Remove and discard all blanking caps.

NOTE:
Make sure the locating tang is installed in the position noted in the removal step.
1 To install, reverse the removal procedure.