Fuel Tank: Service and Repair
CAUTION: Before disconnecting any part of the fuel system it is imperative that all dust, dirt and debris is removed from around the components to prevent ingress of foreign matter into the fuel system.REMOVE
1. Drive the vehicle onto a suitable hoist.
2. Depressurize the fuel system. Fuel Pressure Release
3. Disconnect the battery negative terminal.
4. Disconnect the electrical leads to the fuel tank sender unit. Disconnect the fuel pump electrical multiplug, access to which is gained through the left hand rear wheel arch, the plug is located between the underside of the body and chassis side member.
5. Raise the hoist.
6. Remove the drain plug from the bottom of the fuel tank and drain the fuel into a suitable container that can be sealed afterwards. ENSURE THAT THE TANK IS DRAINED COMPLETELY. Refit the drain plug
7. From underneath the vehicle, disconnect the fuel hose from the inlet side of the fuel filter.
8. Disconnect the fuel return pipe to the fuel tank.
9. Remove the breather hose and three evaporative loss hoses from the fuel tank, seal all hose and pipe openings to prevent ingress of foreign matter.
10. Release the two large hose clamps, securing the inter-connecting hose to tank and filler tube, maneuver the hose up the outside of the filler tube to enable it to be withdrawn from the tank filler neck.
11. With assistance from a second person supporting the fuel tank, remove the four tank fasteners.
12. Tilt the left hand side of the tank downwards and maneuver it out of the chassis frame. Care should be taken to ensure that the fuel feed pipe to filter is not damaged when lowering the tank.
13. Place the tank in a safe area and ensure that all necessary precautions are undertaken to make all personnel within the vicinity aware that the tank will give off residual fuel fumes.
14. If necessary remove the fuel pump from the tank.
REFIT
1. Refit the fuel tank to the chassis, taking care to relocate the fuel feed pipe grommets between the fuel tank and chassis.
2. Reverse the removal procedure. ensuring that the sealing ring, fuel lines, and hose connections are secure.
3. Run the engine and re-check all connections to ensure no fuel leaks exist.
4. Reverse the remaining removal procedure.
5. Recode the radio.