Removal

Access to Luggage Compartment Components
There are no mechanical fixings or retainers to be dealt with to gain access to the battery, fuse/relay center and fuel tank. However, the compartment floor should be removed to release the fuel tank liner.

WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT ALL SAFETY PRECAUTIONS ARE READ AND UNDERSTOOD. Service Precautions

1. Release the fuel filler flap from inside vehicle.
2. Open the engine compartment and install paintwork protection covers.
3. Open the luggage compartment.
4. Remove the battery. Service and Repair
5. Depressurise the fuel system. Fuel Pressure Release
6. Remove the paintwork protection covers and close the engine compartment.
7. Drain the fuel tank using a suitably manually operated (NOT electrically operated) suction pump/tanker.
8. Remove the carpet from the luggage compartment floor.
9. Remove the front liner from the luggage compartment.
10. Remove the side liner, left hand.
11. Remove the side liner, right hand.





12. Convertible/Soft Top vehicles only - remove the fuel tank closing panel.
Remove the seven bolts; three from the top edge and two from each lower bracket to body.
Remove the closing panel.
13. Remove the fuel gauge tank sender unit.
14. Drain the remaining fuel from the tank, through the sender aperture, using the equipment described previously.





15. Release the filler neck gaiter retaining plate.
Remove the bolts which secure the retaining plate.
Remove the retaining plate.
Reposition the gaiter into the luggage compartment area.





16. Release the tank retaining straps (Coupe).
Remove the screw which secures each strap.
Tape or tie the two retaining straps to the top of the luggage compartment.





17. Disconnect the drain hose from the filler neck body aperture.
Release and reposition the securing clip.
Disconnect the drain hose.





18. Disconnect the electrical connector from the fuel filler flap solenoid.





19. Disconnect the harness from the fuel tank connections.
Disconnect the harness from the evaporative loss flange.
Release the harness securing clips from along the tank flange. Move the harness and clips clear of the tank.





20. Remove the straps which secure the harness to the filler neck breather pipe.





21. Disconnect the ground lead from the fuel tank flange.





22. Disconnect the tank breather hose.
Release and reposition the securing clip.
Disconnect the hose from the tank pipe.
23. Raise the vehicle on a ramp.





24. Disconnect the filler neck gaiter drain hose from below the luggage compartment floor.
Release the hose from the clip on the luggage compartment floor.
Reposition the hose through the grommet into the luggage compartment.





25. From under the vehicle, identify the fuel feed and return tank / pipe connections which are located above and slightly to the rear of the axle assembly.
Identify the fuel feed pipe.
Identify the fuel return pipe.





26. Disconnect the fuel feed and return pipes from the fuel tank.
Install special tool 310-054 around the pipe as shown. Press the tool in between the fuel pipe and tank connector to release the quick-fit tangs. While holding the tool firmly in place, pull out the fuel pipe.
Repeat for the second pipe.
Plug the tank outlet connectors and the fuel pipes.
27. Lower the vehicle.





28. Remove the fuel tank.
- Reposition the fuel tank rearwards into the luggage compartment area.
- Lift the tank and turn it through 90° so that the filler neck protrudes rearwards, out of the luggage compartment.
- Remove the tank from the vehicle.

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





29. Remove the breather pipe and fuel filler neck gaiter.
Release the securing ring and remove the gaiter.
Release the hose clip and disconnect the breather hose.





30. Remove the insulation pads from the top of the tank.
Use a sharp knife to very carefully remove the pads.





31. Remove the seal (fuel tank to body) from the fuel line stub pipes at the base of the tank





32. Release the hose clips and disconnect the breather hose from the evaporative loss flange. Slide the hose along the pipe.





33. Remove the evaporative loss flange from the tank.
Remove the locking ring (Tool 412-070) from the evaporative loss flange.
Reposition the flange from the tank.





34. Remove the evaporative loss flange from the tank.
Disconnect the fuel pump electrical link lead from the flange.
Remove the flange and the flange to tank seal.





35. Release the fuel pump mountings.
Slide the lower mounting outwards to release it from the retaining bracket.
Unhook the upper mounting rubber from the retaining bracket.
Reposition the pump to the outside of the tank, through the evaporative loss flange aperture.





36. Disconnect the outlet hose from the fuel pump.
Release and reposition the hose clip.
Disconnect the hose from the pump and place the pump aside.
37. From inside the fuel tank, release the securing clip using HOSE CLIP BRASS WRENCH 412-071. Disconnect and remove the fuel feed hose from the tank.