Fuel tank - r + r and decant fuel

Operation 1040A10 · Fuel tank and components

1.6 TS

Removing

Position the vehicle on the ramp.

Ensure that the ignition key is in the OFF postition, then disconnect the battery negative terminal.

Proceed with the removal - 1040A70 submerged pump assembly complete with level guage control - r + r.

Draw off the fuel from the tank using suitable equipment.

Remove the handbrake boot.

1. Lift up the handbrake lever (1a) and loosen the nut (1b) tensioning the handbrake cables.

Proceed with the removal - 1076B22 rear exhaust silencer - r+r emission control versions.

Proceed with the removal - 1076B26 intermediate exhaust silencer - r+r emission control versions.

1. Undo the fastenings and remove the exhaust pipe intermediate heat shield.

Proceed with the removal - 4450B11 WHEEL (one) rear - R.R. (Right side).

1. Position a hydraulic jack under the rear suspension crossmember.

2. Undo the bolts (2a) and lower the rear suspension crossmember (2b), as necessary, using the hydraulic jack.

1. Loosen the band and disconnect the fuel filler pipe from the tank.

2. Loosen the band and remove the fuel return pipe from the tank.

3. Disconnect the rapid attachments for the fuel vapour supply pipes from the float valves to the fuel vapour separator.

4. Disconnect the rapid attachment for the fuel supply pipe from the multi-purpose valve to the fuel vapour filter.

1. Position a hydraulic jack, complete with suitable support, under the fuel tank.

2. Undo the bolts (2a) and the nuts (2b) securing the fuel tank support belts.

3. Lower the hydraulic jack and remove the fuel tank.

Refitting

Place the fuel tank back in its housing using the hydraulic jack.

Tighten the nuts securing the fuel tank support belts.

Remove the hydraulic jack from under the fuel tank.

Connect the rapid attachment for the fuel vapour supply pipe from the multipurpose valve to the fuel vapour filter.

Connect the rapid attachments for the fuel vapour supply pipes from the float valves to the fuel vapour separator.

Connect the fuel return pipe to the tank and secure it to the band.

Connect thefuel filler pipe to the tank and secure it using the band.

Place the rear suspension crossmember back in its housing using the hydraulic jack and fix it tightening the bolts to the recommended torque.

Remove the hydraulic jack from under the rear suspension crossmember.

Proceed with the refitting - 4450B11 WHEEL (one) rear - R.R. (Right side).

Refit the intermediate heat shield and secure.

Proceed with the refitting - 1076B26 intermediate exhaust silencer - r+r emission control versions.

Proceed with the refitting - 1076B22 rear exhaust silencer - r+r emission control versions.

Adjust the travel of the handbrake lever - 3380A04 handbrake - check travel.

Place the handbrake boot back in its housing.

Proceed with the refitting - 1040A70 submerged pump assembly complete with level guage control - r + r.

Connect the battery terminal (-).

Remove the car from the ramp.

2.0 TS

Removing

Position the vehicle on the ramp.

Ensure that the ignition key is in the OFF postition, then disconnect the battery negative terminal.

Proceed with the removal - 1040A70 submerged pump assembly complete with level guage control - r + r.

Draw off the fuel from the tank using suitable equipment.

Remove the handbrake boot.

1. Lift up the handbrake lever (1a) and loosen the nut (1b) tensioning the handbrake cables.

Proceed with the removal - 1076B22 rear exhaust silencer - r+r emission control versions.

Proceed with the removal - 1076B26 intermediate exhaust silencer - r+r emission control versions.

1. Undo the fastenings and remove the exhaust pipe intermediate heat shield.

Proceed with the removal - 4450B11 WHEEL (one) rear - R.R. (Right side).

1. Position a hydraulic jack under the rear suspension crossmember.

2. Undo the bolts (2a) and lower the rear suspension crossmember (2b), as necessary, using the hydraulic jack.

1. Loosen the band and disconnect the fuel filler pipe from the tank.

2. Loosen the band and remove the fuel return pipe from the tank.

3. Disconnect the rapid attachments for the fuel vapour supply pipes from the float valves to the fuel vapour separator.

4. Disconnect the rapid attachment for the fuel supply pipe from the multi-purpose valve to the fuel vapour filter.

1. Position a hydraulic jack, complete with suitable support, under the fuel tank.

2. Undo the bolts (2a) and the nuts (2b) securing the fuel tank support belts.

3. Lower the hydraulic jack and remove the fuel tank.

Refitting

Place the fuel tank back in its housing using the hydraulic jack.

Tighten the nuts securing the fuel tank support belts.

Remove the hydraulic jack from under the fuel tank.

Connect the rapid attachment for the fuel vapour supply pipe from the multipurpose valve to the fuel vapour filter.

Connect the rapid attachments for the fuel vapour supply pipes from the float valves to the fuel vapour separator.

Connect the fuel return pipe to the tank and secure it to the band.

Connect thefuel filler pipe to the tank and secure it using the band.

Place the rear suspension crossmember back in its housing using the hydraulic jack and fix it tightening the bolts to the recommended torque.

Remove the hydraulic jack from under the rear suspension crossmember.

Proceed with the refitting - 4450B11 WHEEL (one) rear - R.R. (Right side).

Refit the intermediate heat shield and secure.

Proceed with the refitting - 1076B26 intermediate exhaust silencer - r+r emission control versions.

Proceed with the refitting - 1076B22 rear exhaust silencer - r+r emission control versions.

Adjust the travel of the handbrake lever - 3380A04 handbrake - check travel.

Place the handbrake boot back in its housing.

Proceed with the refitting - 1040A70 submerged pump assembly complete with level guage control - r + r.

Connect the battery terminal (-).

Remove the car from the ramp.

3.2 V6

Removing

Position the vehicle on the ramp.

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

Proceed with removal - 1040A70 submerged pump assembly complete with level guage control - r + r.

Draw off the fuel from the tank using suitable equipment.

Remove the handbrake boot.

1. Lift up the handbrake lever (1a) and loosen the nut (1b) tensioning the handbrake cables.

Proceed with removal - 1076B22 rear exhaust silencer - r+r emission control versions.

Proceed with removal - 1076B26 intermediate exhaust silencer - r+r emission control versions.

1. Undo the fastenings and remove the exhaust pipe intermediate heat shield.

Proceed with removal - 4450B08 right rear wheel r r.

1. Position a hydraulic jack under the rear suspension crossmember.

2. Undo the bolts (2a) and lower the rear suspension crossmember (2b), as necessary, using the hydraulic jack.

1. Loosen the band and disconnect the fuel filler pipe from the tank.

2. Loosen the band and remove the fuel return pipe from the tank.

3. Disconnect the rapid attachments for the fuel vapour supply pipes from the float valves to the fuel vapour separator.

4. Disconnect the rapid attachment for the fuel supply pipe from the multi-purpose valve to the fuel vapour filter.

1. Position a hydraulic jack, complete with suitable support, under the fuel tank.

2. Undo the bolts (2a) and the nuts (2b) securing the fuel tank support belts.

3. Lower the hydraulic jack and remove the fuel tank.

Refitting

Place the fuel tank back in its housing using the hydraulic jack.

Tighten the nuts securing the fuel tank support belts.

Remove the hydraulic jack from under the fuel tank.

Connect the rapid attachment for the fuel vapour supply pipe from the multipurpose valve to the fuel vapour filter.

Connect the rapid attachments for the fuel vapour supply pipes from the float valves to the fuel vapour separator.

Connect the fuel return pipe to the tank and secure it to the band.

Connect thefuel filler pipe to the tank and secure it using the band.

Place the rear suspension crossmember back in its housing using the hydraulic jack and fix it tightening the bolts to the recommended torque.

Remove the hydraulic jack from under the rear suspension crossmember.

Proceed with refitting - 4450B08 right rear wheel r r.

Refit the intermediate heat shield and secure.

Proceed with refitting - 1076B26 intermediate exhaust silencer - r+r emission control versions.

Proceed with refitting - 1076B22 rear exhaust silencer - r+r emission control versions.

Adjust the travel of the handbrake lever - 3380A04 handbrake - check travel.

Place the handbrake boot back in its housing.

Proceed with refitting - 1040A70 submerged pump assembly complete with level guage control - r + r.

Connect the negative (-) battery terminal.

Remove the car from the ramps.

1.9 JTD 8V

Removing

Position the vehicle on the ramp.

Disconnect the battery negative terminal.

Proceed with the removal - 1040A70 submerged pump assembly complete with level guage control - r + r.

Draw off the fuel from the tank using suitable equipment.

Remove the handbrake boot.

1. Lift up the handbrake lever (1a) and loosen the nut (1b) tensioning the handbrake cables.

Proceed with the removal - 1076B20 rear exhaust silencer - r + r.

Proceed with the removal - 1076B26 intermediate exhaust silencer - r+r emission control versions.

1. Undo the fastenings and remove the exhaust pipe intermediate heat shield.

Proceed with the removal - 4450B11 WHEEL (one) rear - R.R. (Right side).

1. Position a hydraulic jack under the rear suspension crossmember.

2. Undo the bolts (2a) and lower the rear suspension crossmember (2b), as necessary, using the hydraulic jack.

1. Loosen the band and disconnect the fuel filler pipe from the tank.

2. Loosen the band and remove the fuel return pipe from the tank.

1. Position a hydraulic jack, complete with suitable support, under the fuel tank.

2. Undo the bolts (2a) and the nuts (2b) securing the fuel tank support belts.

3. Lower the hydraulic jack and remove the fuel tank.

Refitting

Place the fuel tank back in its housing using the hydraulic jack.

Tighten the nuts securing the fuel tank support belts.

Remove the hydraulic jack from under the fuel tank.

Connect the fuel return pipe to the tank and secure it to the band.

Connect thefuel filler pipe to the tank and secure it using the band.

Place the rear suspension crossmember back in its housing using the hydraulic jack and fix it tightening the bolts to the recommended torque.

Remove the hydraulic jack from under the rear suspension crossmember.

Proceed with the refitting - 4450B11 WHEEL (one) rear - R.R. (Right side).

Refit the intermediate heat shield and secure.

Proceed with the refitting - 1076B26 intermediate exhaust silencer - r+r emission control versions.

Proceed with the refitting - 1076B20 rear exhaust silencer - r + r.

Adjust the travel of the handbrake lever - 3380A04 handbrake - check travel.

Place the handbrake boot back in its housing.

Proceed with the refitting - 1040A70 submerged pump assembly complete with level guage control - r + r.

Connect the battery terminal (-).

Remove the car from the ramp.

1.9 JTD 16V

Removing

Position the vehicle on the ramp.

Ensure that the ignition key is in the OFF position, then disconnect the negative battery terminal (-).

Proceed with removal - 1040A70 submerged pump assembly complete with level guage control - r + r.

Draw off the fuel from the tank using suitable equipment.

Remove the handbrake boot.

1. Lift up the handbrake lever (1a) and loosen the nut (1b) tensioning the handbrake cables.

Proceed with removal - 1076B20 rear exhaust silencer - r + r.

Proceed with removal - 1076B18 rigid section of exhaust pipe between catalytic converter and silencer - r + r.

1. Undo the fastenings and remove the exhaust pipe intermediate heat shield.

Proceed with removal - 4450B08 right rear wheel r r.

1. Position a hydraulic jack under the rear suspension crossmember.

2. Undo the bolts (2a) and lower the rear suspension crossmember (2b), as necessary, using the hydraulic jack.

1. Loosen the band and disconnect the fuel filler pipe from the tank.

2. Loosen the band and remove the fuel return pipe from the tank.

1. Position a hydraulic jack, complete with suitable support, under the fuel tank.

2. Undo the bolts (2a) and the nuts (2b) securing the fuel tank support belts.

3. Lower the hydraulic jack and remove the fuel tank.

Refitting

Place the fuel tank back in its housing using the hydraulic jack.

Tighten the nuts securing the fuel tank support belts.

Remove the hydraulic jack from under the fuel tank.

Connect the fuel return pipe to the tank and secure it to the band.

Connect thefuel filler pipe to the tank and secure it using the band.

Place the rear suspension crossmember back in its housing using the hydraulic jack and fix it tightening the bolts to the recommended torque.

Remove the hydraulic jack from under the rear suspension crossmember.

Proceed with refitting - 4450B08 right rear wheel r r.

Refit the intermediate heat shield and secure.

Proceed with refitting - 1076B18 rigid section of exhaust pipe between catalytic converter and silencer - r + r.

Proceed with refitting - 1076B20 rear exhaust silencer - r + r.

Adjust the travel of the handbrake lever - 3380A04 handbrake - check travel.

Place the handbrake boot back in its housing.

Proceed with refitting - 1040A70 submerged pump assembly complete with level guage control - r + r.

Connect the negative (-) battery terminal.

Remove the car from the ramps.