Fuel tank - r + r and decant fuel

Operation 1040A10 · Fuel tank and components

1.4 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

Drain the fuel from the tank using suitable equipment and appropriate protection to meet current safety requirements.

1. Release the protection and move it aside.

2. Slacken the handbrake cable adjustment nut.

1.3 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 (-).

Drain the fuel from the tank using suitable equipment and appropriate protection to meet current safety requirements.

1. Lift the rear seat cushion lift the floor covering to gain access to the fuel pump flap.

2. Unscrew retaining bolts (2a) and remove protective cover (2b).

3. Disconnect the electrical connection from the immersed pump assembly complete with gauge.

4. Disconnect the rapid connectors (4a) and (4b) for the fuel supply and return pipes from the submerged pump assembly.

1.4 16v

Proceed with removal - 4450B08 right rear wheel r r

Proceed with removal - 7055B45 right hand rear supplementary wheel arch - r+r

1. Open collars (1a) and disconnect fuel filler pipe (1b) and return pipe (1c).

2. Disconnect the rapid attachments for the fuel vapour recovery pipes from the float valves to the fuel vapour separator.

1.3 JTD 16v

1. Release the protection and move it aside.

2. Loosen the handbrake adjustment nut.

1.4 16v

1. Undo bolt (1a) securing exhaust pipe support rear bracket (1b).

2. Undo bolt (2a) securing exhaust pipe mount front bracket (2b).

1.3 JTD 16v

Proceed with removal - 4450B08 right rear wheel r r

Proceed with removal - 7055B45 right hand rear supplementary wheel arch - r+r

1. Open collars (1a) and disconnect fuel filler pipe (1b) and return pipe (1c).

1.4 16v

1. Undo the fixing nuts (1a) and disconnect the exhaust pipe (1b) from the exhaust manifold with catalytic converter.

Move aside the exhaust pipe, securing it as appropriate to the bodyshell.

1.3 JTD 16v

1. Undo the bolts and lower the exhaust pipe.

1.4 16v

1. Undo the fixing nuts (1a) and disconnect the exhaust pipe (1b) from the exhaust manifold with catalytic converter.

1.3 JTD 16v

1. Open the band retaining the handbrake cable.

2. Undo retaining nuts (2a), remove the clip (2b) and remove the central heat shield (2c).

1.4 16v

1. Open the band retaining the handbrake cable.

2. Undo the nuts (2a), remove the clip (2b) and remove the central heat shield (2c).

1.3 JTD 16v

1. Remove protective cap (1a) and disconnect the handbrake cable from fitting (1b) on the shoes.

1.4 16v

1. Remove the protective cover.

2. Disconnect the handbrake control cable from connection on the rear brake shoes.

1.3 JTD 16v

1. Position a stand supported by a hydraulic jack beneath the tank to support it during removal.

2. Undo the fuel tank bracket retaining bolts.

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

1.4 16v

1. Place an appropriate stand under the fuel tank to support it during removal.

2. Undo the fuel tank bracket retaining bolts.

Lower the hydraulic jack and remove the fuel tank.

1.3 JTD 16v

Refitting

Position the fuel tank on the stand.

Raise the tank until it fits into its seat.

Tighten the bolts securing the fuel tank brackets to the bodyshell to the recommended torque.

Remove the tank stand.

Connect the handbrake cable from the shoes.

Place the protective cap back in position.

Place the centre heat shield back in its housing and secure it using the fastenings.

Fasten the handbrake cable using the band.

Place the rear exhaust pipe back in its housing and tighten the bolt.

Connect the fuel filler pipe and the return pipe and secure them using new bands.

Proceed with refitting - 7055B45 right hand rear supplementary wheel arch - r+r.

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

Disconnect the rapid attachment for the fuel supply pipe from the immersed pump assembly.

Connect the electrical connection to the immersed pump assembly complete with gauge.

Place the protective cover back in its housing and fix it using the bolts.

Put the floor trim back in its place.

Proceed with refitting - 3380A04 handbrake - check travel.

Use the correct equipment and appropriate protection as required by current safety legislation to fill the vehicle with the recommended fuel.

Connect the negative (-) battery terminal.

Remove the car from the ramps.

1.4 16v

Refitting

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

Tighten the bolts securing the fuel mounting brackets to the specified torque.

Remove the fuel tank support stand.

Connect the handbrake control cable to the fitting on the rear brake shoes.

Place the protective covers in their housings.

Refit the rear heat shield in its seating, then secure it with the clip and nuts.

Secure the handbrake cables using the retaining bands.

Secure the brake pipe using the fastenings on the fuel tank.

Refit the exhaust pipe, connect to the exhaust manifold with catalytic converter and tighten the nuts to the specified torque.

Tighten the bolt fixing the exhaust pipe front mounting bracket.

Tighten the exhaust pipe support front bracket securing bolt.

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

Connect the fuel filler pipe and the return pipe. Secure using new bands.

Proceed with refitting - 7055B45 right hand rear supplementary wheel arch - r+r.

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

Proceed with the refitting - 3380A04 handbrake - check travel

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

Use the correct equipment and appropriate protection as required by current safety legislation to fill the vehicle with the recommended fuel.

Connect the negative (-) battery terminal.

Remove the car from the ramps.