Removing Fuel Tank

REMOVING AND INSTALLING FUEL TANK UP TO M1991

WARNING Ensure good ventilation. If approved ventilation for removal of fuel fumes is available, this should be used.

Wear protective gloves. Long-term contact with fuel can cause skin irritation.

Keep a class BE fire extinguisher nearby. Be careful of the danger of sparking, e.g.from circuit breaking, short circuiting etc.

No smoking.

Removal:

1. Empty the fuel from the tank.

2. Remove the two retaining screws from the floor of the luggage compartment and remove the floor.

3. Turn both the bayonet fasteners that secure the cover over the fuel pump using a hexagon key and remove the cover.

4. Unscrew the banjo connector from the fuel line and pull off the electrical connectors to the pump, feed pump and fuel level sensor.

5. Remove the return fuel line connection. Empty the tank before removing. A small quantity of fuel is acceptable.

6. Place the car on a lift. Make sure~that the rear RH lift arm plate is placed as far out on the jack attachment as possible so as not to interfere with removal.
Raise the car and remove the RH rear wheel.






7. Remove both the rubber elbow from the pipe attached to the tank and the breather hose from the filler pipe.

Cover the opening of the filler pipe to prevent fuel from running out and contaminants getting into the tank.

From M1986 (chassis No.Y53CG1003175) detach the breather hose from the upper connector hose.


8. Remove the handbrake cable to the control arm as well as the rubber attachment for the cable from the spring.

9. Undo the nuts on the tank strap. Start with the strap on the RH side and bend the handbrake cable to one side. Lift down the strap on the LH side. Support the tank while working.

10. Lift down the tank LH side first. Make sure that the tank's pipe is not damaged against the plate edge of the bodywork.

Fitting:

Tightening torque for hose clips: 2 Nm (16 ft. LBS.).



Important Danger of cracking if they are over-tightened.

Fit the anti-splash device (butterfly valve) so that the butterfly spindle is vertical.



Important Make sure that the fuel lines are fed through the aperture for the combined tank unit.
The strap fastener must not turn as the bolt is tightened as it is likely to shear at the weld.
After fitting and tightening, the strap must be straight.


Otherwise fit in reverse order.