Installation

Installation
1. Install the fuel feed hose to inside the fuel tank and reposition the hose clip. Tighten the clip using HOSE CLIP BRASS WRENCH 412-071.





2. Install the fuel feed hose to the fuel pump.
Connect the hose to the pump.
Reposition and tighten the hose clip.





3. Install the fuel pump.
Reposition the pump to the inside of the tank, through the evaporative loss flange aperture.
Hook the upper mounting rubber onto the retaining bracket.
Slide the lower mounting onto the retaining bracket.





4. Position the evaporative loss flange to the tank.
Install a new seal to the tank flange.
Connect the fuel pump electrical link lead to the flange.





5. Install the evaporative loss flange to the tank.
Reposition the flange to the tank.
Install the locking ring to the evaporative loss flange using tool 412-070.





6. Reposition the breather hose along the pipe to connect to the evaporative loss flange. Tighten the hose clips.
7. Install the fuel gauge tank sender unit.





8. Install the seal (fuel tank to body) to the fuel line stub pipes at the base of the tank.
Apply adhesive to the tank face of the seal before installation to the stub pipes.





9. Install the insulation pads to the top of the tank.
Apply adhesive to the pads carefully align and locate them onto the tank.





10. Install the fuel filler neck gaiter and breather pipe to the tank.
Install the gaiter and the securing ring.
Connect the breather hose to the fuel tank pipe and secure the hose clip.





11. Install the fuel tank.
- Place the tank into the luggage compartment so that the filler neck protrudes rearwards from the vehicle.
- Lift the tank and turn it through approximately 90° so that the filler neck is on the left side, and the tank positioned towards the front.
- Reposition the fuel tank forwards into the luggage compartment well.

CAUTION: Whilst installing the fuel tank, take care not to damage the left side of the vehicle body with the filler neck.





12. Route the filler neck gaiter drain hose through the luggage compartment floor.
Reposition the hose through the grommet aperture in the luggage compartment. Install the grommet.
Reposition the hose retaining clip to the side of the luggage compartment.





13. Connect the tank breather hose.
Connect the hose to the tank pipe.
Reposition the securing clip.





14. Connect the harness to the fuel tank connections
Position the harness and clips along the tank to the filler flap latch. Install the harness securing clips along the tank top flange.
Connect the harness to the evaporative loss flange.
Secure the harness to the filler neck breather pipe using tie straps.





15. Connect the ground lead to the fuel tank flange.
Tighten to 7-10 Nm.





16. Install new straps which secure the harness to the filler neck breather pipe.





17. Connect the electrical connector to the fuel filler flap solenoid.





18. Connect the drain hose to the filler neck body aperture.
Connect the drain hose
Reposition the securing clip.





19. Install the tank retaining straps.
Release the two retaining straps taped to the top of the luggage compartment.
Install the screw which secures each strap. Tighten to 4-5.5 Nm.





20. Install the filler neck gaiter retaining plate.
- Reposition the retaining plate to align with the securing holes.
- Install the bolts which secure the retaining plate. Tighten to 2.5-3.5 Nm.

NOTE: Reposition the gaiter through the body aperture.

21. Raise the vehicle on a ramp. Vehicle Lifting





22. Connect the fuel feed and return pipes to the fuel tank.
- Install the fuel feed pipe to the Quick Fit Connector. Ensure that the pipe is fully locked in place.
- Repeat for the return pipe. Ensure that the pipe is fully locked in place.

NOTE: Remove the blanking plugs from the tank outlet connectors and the fuel pipes.

23. Install the filler neck drain tube into the clip.
24. Lower the vehicle.
25. Refill the fuel tank.
Install the fuel filler cap and close the flap.
Check for fuel leaks.





26. Convertible/Soft Top vehicles only - install the fuel tank closing panel.
Install the closing panel.
Install the seven bolts; three to the top edge and two to each lower bracket. Tighten to 22-28 Nm.
27. Install the left hand side liner to the luggage compartment.
28. Install the right hand side liner.
29. Install the front liner.
30. Install the battery and battery cover. Service and Repair
31. Refer to the Battery Reconnection Procedure. Service and Repair
32. Install the floor carpet.
33. Close the luggage compartment cover.