Removal

FUEL TANK

WARNING: Ensure that fuel handling precautions are strictly adhered to when carrying out following instructions.

CAUTION: Before disconnecting any part of the fuel system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system.

Remove
1. Position vehicle on hoist.
2. Disconnect battery negative lead.
3. Depressurize fuel system. See Fuel Pressure Release.
4. Drain fuel tank.





5. Loosen clip securing filler hose to fuel tank and disconnect hose.





6. Loosen clip securing breather hose to filter neck and disconnect hose.





7. Using tool LRT-19-002 disconnect vapor separator pipe at green end of "speedfit" connector.
8. Position cloth to absorb fuel spillage.





9. Disconnect fuel feed hose union.
10. Disconnect fuel return hose union.

CAUTION: Plug the connections.





11. Loosen 2 anti-roll [sway] bar link bolts.
12. Mark location of anti-roll [sway] bar straps.
13. Remove 4 bolts securing anti-roll [sway] bar straps and swing bar down clear of fuel tank.
14. Position transmission jack under fuel tank cradle to support fuel tank.

CAUTION: Use a block of wood or hard rubber pad to protect fuel tank.

15. Remove 6 bolts securing fuel tank cradle.
16. Lower fuel tank sufficiently to gain access to fuel pump multiplug.





17. Disconnect multiplug and remove clip securing harness to fuel hoses.
18. With assistance, lower jack, remove fuel tank cradle and fuel tank.

Note: Do not carry out further dismantling if component is removed for access only.





19. Remove 3 screws securing heat shield. Remove heat shield.
20. Release 2 fuel cut-off valves and remove valve and pipe assembly. Remove and discard 2 rubber seals.
21. Loosen clip and remove breather hose from fuel pump.
22. Remove fuel feed and return hoses from fuel pump.





23. Using tool LRT-19-001 remove locking ring securing pump. Withdraw fuel pump from tank.

WARNING: A quantity of fuel will be retained in body of pump. Care must be taken to prevent fuel spillage during above operation.

24. Remove and discard sealing ring.
25. Fit new sealing ring to pump and fit pump.
26. Fit locking ring and using tool LRT-19-001, tighten to 48 Nm (35 lb.ft.).
27. Fit fuel feed and return hoses to pump.
28. Fit breather hose and tighten clip.
29. Fit new fuel cut-off valve seals.
30. Fit valve and pipe assembly.
31. Fit heat shield.

Refit
32. With assistance, locate fuel tank and position cradle.
33. Position jack to support tank.
34. Connect fuel pump multiplug.
35. Raise jack, align cradle and fit and tighten bolts.
36. Raise anti-roll [sway] bar, align straps and fit and tighten bolts.
37. Tighten anti-roll [sway] bar link bolts
38. Clean fuel pipes, connect pipes and tighten unions.
39. Secure harness to fuel pipes with clip.
40. Connect vapor separator pipe.
41. Connect breather hose to filler neck and tighten hose clip.
42. Connect filler hose to fuel tank and tighten hose clip.
43. Reconnect battery negative lead.
44. Run engine and check for leaks.