Note: Observe the precautions given in Chapter 1.
Withdrawal
1. Drain as much fuel as possible before removing the tank.
2. Disconnect the negative cable from the battery and route it away from the terminal. If possible, use a hand pump or siphon to remove any remaining fuel from the bottom of the tank.
3. Guided Chapter 4, do the following:
- a) Disconnect the wiring from the top of the sensor.
- b) Disconnect the supply and return fuel hoses from the sensor.
4. Open the fuel filler flap and remove the screw securing the filler neck to the body.
5. Jack up the rear of the vehicle and place on axle stands. Block the front wheels.
6. Remove the right rear wheel, then unscrew the bolts and remove the wheel arch insert.
7. Disconnect the overflow hose from the filler neck and holder.
8. Loosen the clamp and disconnect the filler hose from the fuel tank, then remove the filler hose from under the car (see illustration).
9. Place a jack in the center of the tank. Insert a piece of wood between the jack saddle and the tank to prevent damage. Raise the tank slightly with a jack.
10. Unscrew the nuts securing the belts to the bottom and remove the belts (see illustrations).
11. Lower the jack while supporting the tank, and then remove it from under the vehicle.
12. If a new tank is to be installed, remove the heat shield from the old one.
13. If the tank is contaminated with sediment or water, remove the sensor (see chapter 4) and flush the tank with clean fuel. The tank is made of synthetic material and should be replaced if damaged. However, in some cases, it may be possible to repair minor leaks or minor damage. Seek advice from a specialist.
Installation
14. Install in the reverse order of removal paying attention to the following:
- a) When lifting the tank back to the working position, make sure that the rubber pads are properly placed and that none of the hoses are pinched between the vehicle body and the tank.
- b) Make sure all tubes and hoses are properly and securely connected.
- c) Connect the ground strap to the terminal on the filler neck.
- d) Tighten the tank mounting bolts with a torque specified specifications.
- e) Finally, fill the tank with fuel and check that there are no leaks.
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