Fuel Tank: Service and Repair

NOTE: Before disconnecting any part of 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. Depressurize fuel system and disconnect the battery negative lead. Fuel Pressure Release
2. Syphon fuel tank into a suitable container that can be sealed afterwards.

WARNING: BE SURE TANK IS DRAINED COMPLETELY.

3. Remove carpet loadspace floor and tailgate.
4. Fold back sound insulation to reveal access panel.
5. Remove access panel.
6. Disconnect electrical multi-plug.





7. Disconnect two fuel line unions from fuel pump.
8. Working underneath vehicle mark location of anti-roll (sway) bar straps.

Fuel Tank R&R:

9. Remove rear anti-roll (sway) bar straps, and allow bar to swing down clear of tank.
10. Remove tank filler and vent hoses at fuel tank.
11. Remove nut and bolt securing right hand side fuel tank strap.
12. Disconnect evaporative control pipe at green end of Speedfit connector.

Special Tool - LRS-19-002:

NOTE: To disconnect Speedfit connector, insert forked end of LRT-19-002 into slots of connector. Press down on collet and simultaneously pull pipe from connector.

13. Remove back two bolts and nut plates securing fuel tank cradle.

Fuel Tank Front Mounting Nuts:

14. Remove front nuts, bolts and washers. Remove fuel tank cradle.
15. With assistance, tilt right hand side of tank upwards and manoeuvre tank through chassis to remove.

REFIT
1. Reverse removal procedure. Ensuring sealing ring, fuel pipe and hose connections are secure.
2. Run engine, check all connections for fuel leaks.