Fuel Tank: Service and Repair

Fuel Tank

Special Service tools







Release tool 5/16" snap coupling
310-054







Fuel tank retaining strap cam adjuster
310-094

Removal

NOTE: This removal/installation procedure is applicable to all tank assembly variants.

1. Remove the battery.
2. Remove the trunk floor carpet.
3. Remove the trunk front liner.
4. Remove the rear lamp assembly interior trim finisher.
5. Remove the trunk seal retainer.
6. Remove the trunk side liner, lefthand.

7. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT ALL THE WARNING, NOTES ARE READ AND UNDERSTOOD.

Remove the trunk side liner, righthand.
8. Drain the fuel tank using a suitable suction pump/tanker. If the On-board Refueling Vapour Recovery (ORVR) system is fitted.







9. From under the vehicle, identify the fuel feed and return tank/pipe connections which are located above and slightly to the rear of the rear axle assembly.
1. Locate the fuel feed pipe.
2. Locate the fuel return pipe.







10. Disconnect the fuel feed and return pipes from the fuel tank
- Fit special tool JD-203 around the pipe as shown. Press the tool in between the fuel pipe and tank connector to release the quick-fit tangs. While holding the tool firmly in, pull out the fuel pipe.
- Repeat for the second pipe.
- Plug the tank outlet connectors and the fuel pipes.







11. From the underside of the vehicle, release the fuel filler latch box drain pipe from the clip on the spare wheel well.







12. Disconnect and reposition the trunk harness if it is routed between the filler tube and the tank breather or pressure relief pipe.
1. Disconnect the lefthand rear lamp harness connector.
2. Disconnect the fuel flap lock actuator connector.
3. If fitted, disconnect the lefthand side marker lamp connector and harness from the underside of the vehicle. Withdraw the marker lamp harness and grommet through the trunk floor access hole.
4. Release the harness securing clip from the mounting bracket.
- Withdraw the trunk harness from between the filler tube and the breather pipe or pressure relief pipe.







13. Disconnect the tank harness connections.
1. If fitted, disconnect the wiring to the accelerometer.
2. Disconnect the wiring to the fuel level sensor harness.
3. Disconnect the wiring to the fuel pump connector.
4. If fitted, disconnect the wiring to the pressure sensor connector.







14. Remove fuel filler latch box drain pipe.
1. Cut and remove the ratchet strap securing the drain pipe to the filler tube.
2. Disconnect the drain pipe from the fuel filler latch box.
3. Pull the drain pipe through the body grommet and remove.







15. Disconnect the vapour outlet pipe.
- Release the quick-fit coupling.
- Plug the vapour pipes.







16. Disconnect the fuel filler latch box from the filler tube.
- Open the fuel filler flap and remove the filler cap.
1. Remove the spring ring securing the fuel filler latch box to the filler neck.
2. Pull the fuel filler latch box free of the filler tube.







17. Detach the tank retaining straps.
- Tape or tie the two retaining straps/brackets to the rear scuttle to allow tank removal.







18. On non-ORVR vehicles, disconnect the trunk lid lefthand strut rear pivot.
- Place a suitable support under trunk lid or tie to exterior mirror.
1. Using a screwdriver, release clip at rear end of strut, withdraw end from trunk lid pivot and lower strut.







19. Disconnect the tank ground cable from the vehicle body.
20. Remove the tank from the vehicle.
21. Drain any remaining fuel from the tank.

Installation
1. Fit the fuel tank assembly.






2. Re-connect the tank ground cable to the vehicle.
- Tighten to 12 Nm.
3. On non-ORVR fuel tanks, position the trunk lid lefthand strut between the filler tube and the breather pipe.
4. Fully seat the tank into position, ensuring that no harness wiring is trapped.







5. On non-ORVR vehicles, reconnect the trunk lid lefthand strut rear pivot.
1. Fit the retaining clip on to the end of the trunk lid strut and fit the strut to the trunk lid pivot. Re-position retaining clip to secure the strut.
- Remove any temporary trunk lid supports and check that the lid operates correctly.







6. NOTE: Make sure the special tool locating peg is correctly installed to the cam.

Using the special tool, tighten the fuel tank retaining straps.
1. Rotate the cam clockwise to a torque of 6 Nm.

NOTE: Using an open ended wrench, maintain the torque on the special tool.

2. Tighten the fuel tank retaining strap bolt to 25 Nm.







7. Connect the filler neck to the fuel filler latch box seal.
1. Fit the fuel filler latch box seal over the filler neck.
2. Secure with the spring ring
- Fit the fuel filler cap.







8. Connect the vapour outlet pipe.
- Unplug the vapour pipes.
- Reconnect the tank and underfloor vapour pipes via the quick-fit coupling.







9. Fit the fuel filler latch box drain pipe.
1. Feed the drain pipe through the floor grommet.
2. Connect the drain pipe to the fuel filler latch box stub pipe.
3. Tie the drain pipe to the filler tube using a ratchet strap. Trim strap.







10. Reconnect the trunk harness connections.
1. If fitted, connect the wiring to the accelerometer.
2. Connect the wiring to the fuel level sensor harness.
3. Connect the wiring to the fuel pump connector.
4. If fitted, connect the wiring to the pressure sensor connector.







11. Reconnect the lefthand side trunk harness if it has been necessary to move it for access. Route the harness behind both the filler tube and breather or pressure relief pipe.
1. Fit the harness securing clip to the mounting bracket.
2. Connect the fuel flap lock actuator connector.
3. Connect the lefthand rear lamp harness connector.
4. If applicable, feed the side marker lamp harness through the access hole in the floor and reseat the sealing grommet.
- On the underside of the vehicle, fit the side marker lamp connector and fix the harness to the securing clips.







12. On the underside of the vehicle, fit the drain pipe to the securing clip.







13. On the underside of the vehicle, reconnect the fuel feed and return pipes.
- Remove the plugs from the tank and fuel feed and return pipes.
1. Push the fuel feed pipe into the quick-fit tank connector. Ensure the pipe is fully home.
2. Push the fuel return pipe into the quick-fit tank connector. Ensure the pipe is fully home.
14. Fit the trunk side liner, lefthand.
15. Fit the trunk side liner, righthand.
16. Fit the trunk seal retainer.
17. Fit the rear lamp assembly interior trim finisher.
18. Fit the trunk front liner.
19. Fit the trunk floor carpet.
20. Ensure that the fuel feed pipes in the engine compartment are reconnected after tank draining.
21. Re-fit the battery.
22. Carry out a leak test of the evaporative emissions system.