Fuel Tank: Service and Repair
FUEL TANK REPLACEMENT
4 Door Models:
^ Remove:
- Spare wheel cover.
- Trunk floor carpeting.
- Rear light cover.
- Rear panels.
- Side panels.
5 Door Models:
^ Remove:
- Left rear wheel-arch cover.
- Floor panels behind rear seat. (Fold down seatback to reach nuts and then draw panel forwards and upwards).
- Spare wheel cover carpeting.
Remove:
^ Tank unit cover.
^ Hoses from tank unit (Remove quick-release coupling by simultaneously applying pressure on hose and sliding sleeve upwards).
^ Strip clamps from filler pipe.
^ Electrical connectors and press out rubber grommets.
^ Withdraw electrical leads from tank unit.
NOTE: Wear a mask to avoid inhaling fuel vapor.
Remove:
^ Hose clip around nut on tank unit.
^ Nut with tool P/N 9995448.
^ Lift tank unit.
^ Lay tank unit to one side. (Keep it in a plastic bag or similar to avoid dirt and smell).
Drain Fuel
^ Use tank draining unit.
^ Draw up fuel through filler hole in tank unit.
Remove Cover and Fuel Tank
^ Remove the four screws.
Slack Off Front Tank Fixing
^ Completely remove retaining strap screws.
^ Slack off outer screws approx. 10 mm.
^ Remove retaining strap from front tank fixing.
Remove:
^ Strut under tank.
^ Nut on tank fixing upper side.
Remove Tank From Body
^ Remove tank so that it rests against the loose fixing brackets.
Remove Drive Shaft
^ Mark off front and rear of drive shaft against respective drive flanges.
^ Remove bolts from front and rear flanges.
^ Remove support bearing and bracket.
^ Remove drive shaft.
NOTE: When slacking off rear flange, mark positions of bolts since they also act as balance weights. Do not use tools or force to remove jointing.
Trolley Jack
^ Place trolley jack with fixture 5972 under tank.
Remove Tank
^ Remove front fixing.
^ Drop tank slightly and pull forwards.
^ Remove expansion nipple hose located over drive shaft tunnel.
^ Remove tank.
^ Remove protective plates from tank.
Fit Protective Plates
^ Check that heat shield insulation fixing lugs fault-free.
^ Fit protective plates to tank.
^ Check no loose matter in tank.
Fit Abrasion Protector to Tank
^ Fit 6 self-adhesive foam-plastic tabs.
^ Foam plastic is Part No. 1215113-0.
Lift Tank
^ Slack off nuts for bracket rear retaining strap fixing (do not remove completely).
^ Lift tank under body. Use trolley jack with fixture 5972.
Fit Tank
^ Connect hose to expansion nipple and tighten hose clip.
^ Lift tank back to correct position. Note right fixing when tank is finally in position.
Fit Front Fixing
^ Retighten the two outer screws which were slacked off (a few turns).
^ Tank will now hang down slightly at front.
Fit Drive Shaft
^ Fit support bearing bracket (with drive shaft).
^ Fit front flange to marks.
^ Use new bolts and nuts.
Tightening torque 50 Nm (37 ft lb).
NOTE: Rear flange bolts should be replaced by new ones each of the same length. (Bolts can have differing lengths when they also act as balance weights.) Use P/N 9995561 as back support.
Connect Support Strap to Front Fixing
^ Fit support strap and then finally tighten front fixing.
^ Tighten support strap bracket.
Fit:
^ Right side fixing. Pull apart heat shield and sound insulation.
^ Fuel tank strut.
Fit Tank Unit
^ Fit seal in tank opening.
^ Grease tank unit contact surface with a thin layer of petroleum jelly (glycerol).
^ Lower tank unit into tank, taking care not to damage pump fixings against tank wash-plates.
^ Locate position marks against tank plastic joints.
^ Enter new nut and tighten with tool P/N 9995448.
NOTE: During installation of new tank, nuts must also be new, otherwise there is a risk of leakage.
Connect Electrical Leads
^ Thread leads, fit rubber grommets, and reconnect connectors.
^ Strip band as previously.
Fit:
^ Hoses.
^ Tank unit cover.
^ Refill with fuel.
Carry Out Function Check
^ Check sealing, pump and measurement functions.
4 Door Models:
^ Fit:
- Side panels.
- Rear panels.
- Rear wheel covers.
- Trunk floor carpeting.
- Spare wheel cover.
5 Door Models:
^ Fit:
- Spare wheel cover carpeting.
- Floor panels behind seatback.
- Left rear wheel-arch cover.