Fuel Tank: Service and Repair

WARNING: Disconnect battery ground strap before beginning to work on the fuel/electrical system. Do not smoke or have anything in the area which can ignite or cause sparks.

NOTE: Some variants are equipped with optional 82 liter fuel tanks and/or independent rear suspension. There are no R & R procedures specific to the 82 liter tanks or IRS equipped cars found in the OE manuals.

Therefore the procedure below should be used and adapted for use on 82 liter fuel tank and IRS equipped cars.




1. Drain fuel from tank using suitable pumping equipment.
2. Remove floor mat and panel from trunk.





3. Disconnect wiring harness connector to sending unit. Remove wires from connector.
4. Disconnect ground wire to sender. Push wires through grommet.
5. Remove cover for access to tank sending unit.





NOTE: Station wagons only: To gain access to the sending unit cover, fold rear seat forward, remove front mat in luggage compartment. Remove three screws, pull mat forward.





6. All models: Disconnect from the fuel tank sending unit:
a. Breather hose C
b. Return hose A
c. Supply hose B
d. Filler hose D
e. Wiring harness from clip E





7. Place jack and support stand under tank as shown. Loosen the two rear bolts (left arrows). Remove four screws and panel (right arrow) at front of tank.
8. Remove fuel tank from the vehicle.





9. Unscrew fuel gauge sender cap using a wide blade screwdriver and hammer. Remove tank sender and seal. Transfer parts to new fuel tank.
10. Install rubber seal in neck of tank. Lubricate inside of seal.
11. Install fuel tank sending unit. Align it with the moulded joint (arrows) on tank.
12. Apply rustproofing compound to exposed metal portions of tank sender.

CAUTION: With tape or rubber caps, protect fuel sender openings from overspray.

13. Hand-tighten fuel gauge sender to:

22 ft-lb (30 Nm)





14. Position fuel tank in vehicle with jack and support stand. Make sure that evaporative system hose is not kinked.
15. Attach mounting straps and support plate at front of tank and tighten retaining bolts. Tighten rear retaining bolts. Install panel at front of tank.





16. Push fuel sender wires through grommet and secure to retaining clip # E.
17. Reconnect:
a. Filler hose # D
b. Supply hose # B
c. Return hose # A
d. Breather hose # C





18. Connect fuel sender ground wire to the body. Reinstall terminals for fuel gauge sender wires into connector. Check for proper positions. Rejoin connector together. Secure wiring to filler tube with a tie strap.
19. Fill tank with fuel.
20. Reconnect battery ground strap. START engine and check fuel gauge for proper operation and fuel tank for leaks.
21. Reinstall fuel gauge sender cover, all panels and mats.