Fuel tank - removal and refitting

Fuel system: single-point injection models / Fuel tank - removal and refitting

Warning: Observe the
precautions in Section 1 before working on any component in the fuel system.

Removal
1 Before the tank can be removed, it must be drained of as much fuel as possible. As no drain plug is provided, it is preferable to carry out this operation with the tank almost empty.

2 Disconnect the battery negative cable and position it away from the terminal. Using a hand pump or syphon, remove any remaining fuel from the bottom of the tank.

3 Refer to Section 7 and carry out the following:
a) Disconnect the wiring harness from the top of the pump sender unit at the multiway connector.

b) Disconnect the fuel supply and return hoses from the pump/sender unit 4 Select first gear and chock the front roadwheels. Remove the centre caps and slacken the right hand rear roadwheel bolts.

5 Raise the rear of the vehicle, support it securely on axle stands (see “Jacking and vehicle support”) and remove the right hand rear roadwheel.

6 Refer to Chapter 4C and unhook the exhaust tailbox from its mounting bracket.

7 With reference to Chapter 9, detach the handbrake cable and its mounting bracket from the rear axle beam.

8 Refer to Chapter 10 and unbolt the right hand axle beam mounting from the vehicle underside. Support the axle on blocks to prevent straining the bushes.

9 Position a trolley jack under the centre of the tank. Insert a block of wood between the jack head and the tank to prevent damage to the tank surface. Raise the jack until it just takes the weight of the tank.

10 Working inside the rear right hand wheel arch, slacken and withdraw the screws that secure the tank filler neck to the inside of the wheel arch. Open the fuel filler flap and peel the rubber sealing flange away from the bodywork.

11 Detach the breather hoses from the filler neck, making a note of their order of fitment.

12 Remove the retaining screws from the tank securing straps, keeping one hand on the tank to steady it, as it is released from its mountings.

13 Lower the jack and tank away from the underside of the vehicle; disconnect the charcoal canister vent pipe from the port on the filler neck as it is exposed. Locate the earthing strap and disconnect it from the terminal at the filler neck.

14 If the tank is contaminated with sediment or water, remove the fuel lift pump/sender unit (see Section 7 ) and swill the tank out with clean fuel.

Refitting
15 Refitting is the reverse of the removal procedure noting the following points.

a) When lifting the tank back into position make sure the mounting rubbers are correct/y positioned and take great care to ensure that none of the hoses become trapped between the tank and vehicle body.

b) The large breather hose must be secured to the filler neck before the tank is secured in position.

c) Ensure that all breather pipes and hoses are correctly routed, free of kinks and securely held in position with their retaining clips.

d) Reconnect the earth strap to its terminal on the filler neck.

e) Tighten the tank retaining strap bolts to the specified torque.

f) If a new tank has been fitted, it must be coated with undersea/ before the vehicle is brought back into service.

g) On completion, refill the tank with fuel and check for signs of leakage prior to taking the vehicle out on the road.