Fuel Tank: Service and Repair

NOTE: Operations within fuel tank assembly must only be performed with use of screwdriver JD 175.


FUEL TANK
- Open the luggage compartment and displace the right-hand front side liner.





- Displace the fuel pump relay (silver relay on black 1 yellow base) from mounting at rear of hockey stick panel and remove the relay (Fig. 1).
- Crank the engine to depressurize the fuel system. Disconnect and remove the battery.
- Remove the spare wheel.
- Empty the fuel tank into a explosion proof container using suitable fireproof equipment.
- Raise the vehicle on a ramp.

Fig. 2:

- Remove the clips securing the fuel supply and return hoses (Fig. 2).
- Disconnect the hoses from the tank. Fit protective plugs to the hoses and the tank.
- Lower the vehicle.
- Displace and remove left-hand side liner.
- Remove compartment floor carpet.
- Remove the boot seal from the front flange and remove the front liner to flange trim.
- Displace and remove the spare wheel securing stud.

Fig. 3:

- Release securing nuts and bolts and remove the fuel tank retaining straps (1 Fig. 3).

Fig. 4:

- Disconnect gauge unit harness connections (1 Fig. 4) and displace harness.
- Disconnect pump harness multi-plug and displace harness (3 Fig. 3).
- Release P clips securing purge and overflow pipes.
- Note and disconnect plastic purge and overflow pipes from the evaporative loss flange (2 Fig. 3).
- Position a suitable support to prop the boot lid open.

Fig. 5:

- Displace the left-hand and right-hand boot lid gas strut lower ball mountings (1 Fig. 5).
- Remove securing nuts and bolts (2 Fig 5) and displace the left-hand and right-hand hockey stick panels (3 Fig. 5).

Fig. 6:

- Slacken the fuel filler neck to tank hose securing clips (1 Fig. 6).
- Remove the fuel filler neck retaining bracket (2 Fig. 6).

Fig. 7:

- Open the fuel filler flap and remove the filler neck seal securing screws (1 Fig. 7). Displace and remove the retaining plate (2 Fig. 7), seal and filler neck.
- Remove fuel filler neck hose (3 Fig. 6) and securing clips.
- Disconnect drain tubes (4 Fig. 6) at both sides from the boot aperture drain stub pipes (5 Fig. 6). Withdraw and remove tank assembly from the vehicle, place on bench.
- Remove seal from tank at feed and return stub pipes.
- Cut insulation pad from tank.

Fig. 8:

- Release clip and disconnect breather hose (1 Fig. 8) from evaporative loss flange.
- Using tool JD 174, displace and remove the evaporative loss flange retaining ring (2 Fig. 8).
- Reposition the flange (3 Fig. 8) for access to the fuel pump harness multi-plug, disconnect the multi- plug.
- Using screwdriver JD 175 release the internal hose (4 Fig. 8) securing clips and disconnect hoses from the pump assembly.
- Displace and remove the pump assembly (5 Fig. 8).
- Displace and remove the pump rubber mounting (6 Fig. 8).
- Using tool 18G 1001 displace and remove the fuel gauge unit securing ring.
- Remove the gauge unit and seal (7 Fig. 8).
- Fitting a replacement tank is the reversal of the removal procedure.
- Refit the components from the original tank.
- Refer to operations 19 45 08 and 19 55 24 for details of fitment of pump assembly and evaporative loss flange.
- Ensure new O-rings and seals are fitted. Ensure all electrical connections are clean and secure.
- Check all flange, hose and pipe connections for security and signs of leakage.