Fuel Tank: Service and Repair

Fuel Tank and Lines - Fuel Tank

Removal and Installation




Special Tool(s)


Removal

WARNINGS:

Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes" signs about the vehicle.

Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete.

Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs. Failure to follow these instructions may result in personal injury.

After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.

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.

If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.

If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention.

Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.


All vehicles

1. Open the fuel filler flap from inside vehicle.

2. Release the fuel system pressure.

3. Remove the battery.

4. Drain the fuel tank.

5. Remove the luggage compartment front trim panel.

6. Remove the left-hand luggage compartment side trim panel.

7. Remove the right-hand luggage compartment side trim panel.

8. Remove fuel tank filler pipe retaining plate.



1. Remove the fuel tank filler pipe retaining bolts.
2. Remove fuel tank filler pipe retaining plate.


Vehicles with convertible top




9. Remove the fuel tank access panel.


Vehicles without convertible top

10. NOTE: Left-hand shown, right-hand similar.
Reposition the fuel tank support straps.



1. Remove the fuel tank support strap retaining bolts.
2. Reposition the fuel tank support straps.


All vehicles




11. Disconnect the fuel tank filler pipe drain hose.



12. Disconnect the fuel tank filler pipe flap actuator electrical connector.



13. Detach the fuel tank wiring harness.



14. NOTE: Vehicles with on-board refueling vapour recovery shown, vehicles without on-board refueling vapour recovery similar. Disconnect the fuel tank breather hose.

15. Raise and support the vehicle.

16. Guide the fuel tank filler pipe drain hose through the luggage compartment floor.
- Detach the fuel tank filler pipe drain hose
- Guide the fuel tank filler pipe drain hose through the luggage compartment floor.

17. Using the special tool disconnect the fuel pipe.

18. Lower the vehicle.




19. CAUTIONS:

Make sure the left-hand side of the vehicle body is not damaged by the fuel tank filler pipe on removal of the fuel tank.

Make sure the luggage compartment wiring harness is not damaged on removal of the fuel tank.

Remove the fuel tank.

Reposition the fuel tank rearwards into the luggage compartment area.

Raise the fuel tank and rotate it through 90� counterclockwise until the fuel tank filler pipe protrudes rearwards, out of the luggage compartment.

Remove the fuel tank.


Installation

All vehicles

1. To install, reverse the removal procedure.

Vehicles with convertible top



2. Tighten to 25 Nm.