FUEL TANK - R + R FOR REPLACEMENT

Operation 1040A14 · FUEL TANK AND COMPONENTS

1.8, 2.2

Removing

- Position the vehicle on a lift.

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

Op. 4450B08 RIGHT REAR WHEEL - R.R

Op. 7055B45 RIGHT REAR WHEEL ARCH LINER - R.R

Op. 1040A30 FUEL FILLER PIPE ASSEMBLY- R + R

Op. 1076B20 REAR EXHAUST SILENCER - R + R

Op. 1076B30 FRONT EXHAUST SILENCER - R + R

Op. 1040A10 FUEL TANK - R + R AND DECANT FUEL

1. Release the fuel vapour inlet and outlet pipes to the activated charcoal filter from the fastenings on the tank.

1. Release the activated charcoal filter for fuel vapours from the mount on the tank and remove with the pipes.

1. Disconnect the electrical connection from the submerged pump assembly complete with level gauge.

2. Disconnect the rapid connector for the rear fuel supply pipe, submerged pump assembly side complete with level gauge.

1. Remove the ring nut (1a) using the tool (1b).

2. Remove the submerged fuel assembly complete with level gauge control.

3. Remove the O-ring.

1. Release the rear fuel supply pipe from the fastenings on the fuel tank and remove it.

2. Loosen the collar and remove the antiregurgitation pipe from the fuel tank.

3. Loosen the collar and remove the fuel filler pipe from the fuel tank.

1. Undo nuts (1a), remove clips (1b) and remove the lower fuel tank protection (1c).

2. Remove the fuel tank support belt.

Refitting

- Place the fuel tank support belt back in its housing.

- Replace the lower fuel tank protection and secure it using the bands and the nuts.

- Connect the fuel filler pipe to the fuel tank and secure with the collar.

- Connect the antiregurgitation pipe to the fuel tank and secure with the collar.

- Refit the rear fuel delivery pipe to its seat on the tank.

1. Place a new O-Ring seal in the housing on the fuel tank collar and make sure that it is correctly positioned.

2. Position the submerged pump assembly complete with level gauge control in its housing.

3. Tighten the ring nut (3a) securing the submerged pump assembly complete with level gauge using the tool (3b).

- Connect the rapid connector for the rear fuel supply pipe, submerged pump assembly side complete with level gauge.

- Connect the electrical connection to the submerged pump assembly complete with level gauge.

- Refit the activated carbon filter for fuel vapours complete with pipes and secure to the bracket on the tank.

- Fasten the fuel vapour inlet and outlet pipes to the activated charcoal filter to the fastenings on the tank.

Op. 1040A10 FUEL TANK - R + R AND DECANT FUEL

Op. 1076B30 FRONT EXHAUST SILENCER - R + R

Op. 1076B20 REAR EXHAUST SILENCER - R + R

Op. 1040A30 FUEL FILLER PIPE ASSEMBLY- R + R

Op. 7055B45 RIGHT REAR WHEEL ARCH LINER - R.R

Op. 4450B08 RIGHT REAR WHEEL - R.R

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

1.9 JTD 8v, 1.9 JTD 16v, 2.4 JTD 20v

Removing

- Position the vehicle on a lift.

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

Op. 7050A20 ONE-PIECE REAR SEAT CUSHION - R.R.

Op. 1040A10 FUEL TANK - R + R AND DECANT FUEL

1. Undo the ring nut (1a) using the tool (1b).

2. Remove the submerged fuel assembly complete with level gauge control.

3. Remove the O-ring.

Refitting

- Place a new O-Ring seal in the housing on the fuel tank collar and make sure that it is correctly positioned.

- Position the submerged pump assembly complete with level gauge control in its housing.

Fit the submerged pump assembly complete with level gauge ensuring that the reference is in line with the arrow on the tank.

- Tighten the ring nut securing the submerged pump assembly complete with level gauge using the tool.

Op. 1040A10 FUEL TANK - R + R AND DECANT FUEL

Op. 7050A20 ONE-PIECE REAR SEAT CUSHION - R.R.

- Connect the negative battery terminal.

- Remove the vehicle from the lift.