FUEL TANK - R + R AND DECANT FUEL

Operation 1040A10 · FUEL TANK AND COMPONENTS

2.0 16V

Removing

- Position the vehicle on a lift.

- Disconnect the negative battery terminal.

- Draw off the fuel from the tank using a special tool.

1. Undo the fixing bolts (1a) and remove the passenger compartment carpet (1b).

1. Undo the fixing bolts.

2. Remove the protective cover for the submerged pump housing.

1. Disconnect the electrical connection for the submerged pump.

2. Disconnect the fuel supply and return pipes from the rapid connectors.

1. Open the band and release the tank fuel filler pipe.

2. Undo the lower bolt fixing the fuel filler pipe to the bodyshell.

3. Open the retaining band and disconnect the front anti-evaporation pipe.

- Position a hydraulic jack with a suitable support under the fuel tank.

1. Undo the bolts fixing the tank to the bodyshell.

2. Lower the hydraulic jack, disconnect the fuel reflux pipe (2a) and remove the fuel tank (2b).

- Disconnect the anti-evaporation pipes acting on the retaining bands.

Refitting

- Fit the fuel tank on the support tool and fit it in the special housing.

- Connect the anti-evaporation pipes and restore the fastenings using the bands.

- Tighten the fuel tank fixing bolts to torque.

- Remove the hydraulic jack and support from underneath the tank.

- Connect the tank fuel filler pipe.

- Connect the fuel reflux pipe to the tank.

- Connect the electrical connection for the submerged pump.

- Connect the fuel supply and return pipes to the rapid connectors.

- Fit the protective cover for the subemerged pump housing and tighten the fixing bolts.

- Fit the passenger compartment carpet and tighten the fixing bolts.

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

2.3 JTD 16V

Removing

- Position the vehicle on a lift.

- Disconnect the negative battery terminal.

- Draw off the fuel from the tank using a special tool.

1. Undo the fixing bolts (1a) and remove the passenger compartment carpet (1b) illustrated.

1. Undo the fixing bolts.

2. Remove the protective cover for the submerged pump housing.

1. Disconnect the electrical connection for the submerged pump.

2. Disconnect the fuel supply and return pipes from the rapid connectors.

1. Disconnect the tank fuel filler pipe.

- Position a hydraulic jack with a suitable support under the fuel tank.

1. Undo the bolts fixing the tank to the bodyshell.

2. Lower the hydraulic jack, disconnect the fuel reflux pipe (2a) and remove the fuel tank (2b).

Refitting

- Fit the fuel tank on the support tool and fit it in the special housing.

- Tighten the bolts fixing fuel tank support belts to torque.

- Remove the hydraulic jack and support from underneath the tank.

- Connect the tank fuel filler pipe.

- Connect the fuel reflux pipe to the tank.

- Connect the electrical connection for the submerged pump.

- Connect the fuel supply and return pipes to the rapid connectors.

- Fit the protective cover for the subemerged pump housing and tighten the fixing bolts.

- Fit the passenger compartment carpet and tighten the fixing bolts.

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

2.0 JTD 8V

Removing

- Position the vehicle on a lift.

- Disconnect the negative battery terminal.

- Draw off the fuel from the tank using a special tool.

1. Undo the fixing bolts (1a) and remove the passenger compartment carpet (1b) illustrated.

1. Undo the fixing bolts.

2. Remove the protective cover for the submerged pump housing.

1. Disconnect the electrical connection for the submerged pump.

2. Disconnect the fuel supply and return pipes from the rapid connectors.

See in Op. 1040B62

1. Disconnect the tank fuel filler pipe.

- Position a hydraulic jack with a suitable support under the fuel tank.

1. Undo the bolts fixing the tank to the bodyshell.

2. Lower the hydraulic jack, disconnect the fuel reflux pipe (2a) and remove the fuel tank (2b).

Refitting

- Fit the fuel tank on the support tool and fit it in the special housing.

- Tighten the bolts fixing fuel tank support belts to torque.

- Remove the hydraulic jack and support from underneath the tank.

- Connect the tank fuel filler pipe.

- Connect the fuel reflux pipe to the tank.

See in Op. 1040B62

- Connect the electrical connection for the submerged pump.

- Connect the fuel supply and return pipes to the rapid connectors.

- Fit the protective cover for the subemerged pump housing and tighten the fixing bolts.

- Fit the passenger compartment carpet and tighten the fixing bolts.

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

2.8 JTD 8V

Removing

- Position the vehicle on the lift.

- Disconnect the negative battery terminal.

- Draw off the fuel from the tank using a special tool.

1. Undo the fixing bolts (1a) and remove the passenger compartment carpet (1b) illustrated.

1. Undo the fixing bolts.

2. Remove the protective cover for the submerged pump housing.

1. Disconnect the electrical connection for the submerged pump.

2. Disconnect the fuel supply and return pipes from the rapid connectors.

See in Op. 1040B62

1. Disconnect the tank fuel filler pipe.

- Position a hydraulic jack with a suitable support under the fuel tank.

1. Undo the bolts fixing the tank to the bodyshell.

2. Lower the hydraulic jack, disconnect the fuel reflux pipe (2a) and remove the fuel tank (2b).

Refitting

- Fit the fuel tank on the support tool and fit it in the special housing.

- Tighten the bolts fixing fuel tank support belts to torque.

- Remove the hydraulic jack and support from underneath the tank.

- Connect the tank fuel filler pipe.

- Connect the fuel reflux pipe to the tank.

See in Op. 1040B62

- Connect the electrical connection for the submerged pump.

- Connect the fuel supply and return pipes to the rapid connectors.

- Fit the protective cover for the subemerged pump housing and tighten the fixing bolts.

- Fit the passenger compartment carpet and tighten the fixing bolts.

- Connect the negative battery terminal.

- Remove the vehicle from the lift.