FUEL TANK - R + R AND DECANT FUEL

Operation 1040A10 · FUEL TANK AND COMPONENTS

1.9 JTS, 2.2 JTS

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.

1. Undo the bolts (1a) and remove the access cover (1b) for the submerged pump assembly complete with level gauge.

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

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

1. Disconnect the rapid connector for the breather pipe, fuel tank side.

2. Disconnect the rapid connector for the fuel filler pipe, fuel tank side.

1. Disconnect the quick-release connectors for the fuel vapour recovery pipes.

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

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

1. Lower the hydraulic jack slowly and remove the fuel tank.

Refitting

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

- Place the fuel tank support belts back in their housings and secure them tightening the bolts to the recommended torque.

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

- Connect the quick-release connectors for the fuel vapour recovery pipes.

- Connect the rapid connector for the fuel filler pipe, fuel tank side.

- Connect the rapid connector for the breather pipe, fuel tank side.

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

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

- Place the access cover to the submerged pump assembly complete with level gauge back in its housing and secure it using the bolts.

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

1. Undo the bolts (1a) and remove the access cover (1b) for the submerged pump assembly complete with level gauge.

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

2. Disconnect the rapid connectors for the fuel supply and return pipes, submereged pump assembly side complete with level gauge.

1. Disconnect the rapid connector for the breather pipe, fuel tank side.

2. Disconnect the rapid connector for the fuel filler pipe, fuel tank side.

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

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

1. Lower the hydraulic jack slowly and remove the fuel tank.

Refitting

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

- Place the fuel tank support belts back in their housings and secure them tightening the bolts to the recommended torque.

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

- Connect the rapid connector for the fuel filler pipe, fuel tank side.

- Connect the rapid connector for the breather pipe, fuel tank side.

- Connect the rapid connectors for the fuel supply and return pipes, submereged pump assembly side complete with level gauge.

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

- Place the access cover to the submerged pump assembly complete with level gauge back in its housing and secure it using the bolts.

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

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

3.2 JTS

Removing

Op. 4450B13 REAR WHEELS (TWO) - R.R

Op. 2720C10 DIFFERENCIAL UNIT - R.R.

Op. 2410A18 TRANSMISSION WITH JOINTS INCLUDED - R.R.

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

1. Undo the bolts (1a) and move the access cover (1b) for the submerged pump assembly to one side.

1. Disconnect the electrical connection for the submerged pump assembly.

2. Disconnect the fuel supply and return pipe rapid connectors.

1. Undo the nuts and remove the heat shield for the fuel tank.

1. Disconnect the rapid connector for the breather pipe, tank side.

2. Using pliers (2a), disconnect the rapid connector for the fuel filler pipe (2b), tank side.

1. Position a hydraulic jack with a suitable tool under the fuel tank.

2. Undo the fastenings and remove the fuel tank support belts.

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

Refitting

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

- Place the support belts back in their housings and secure them tightening the fastenings to the recommended torque.

- Using the tool used for the removal, connect the rapid connector for the fuel filler pipe, tank side.

- Place the fuel tank heat shield in position and secure it using the nuts.

- Connect the fuel supply and return pipe rapid connectors.

- Connect the electrical connection for the submerged pump assembly.

- Place the submerged pump assembly access cover back in its housing and secure it using the bolts.

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

Op. 2410A18 TRANSMISSION WITH JOINTS INCLUDED - R.R.

Op. 2720C10 DIFFERENCIAL UNIT - R.R.

Op. 4450B13 REAR WHEELS (TWO) - R.R