Fuel Tank, Removal and Refurbishment

Removing fuel tank

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NOTE: This is best done when tank is empty or almost empty as otherwise tank will be heavy!

Perform fuel pressure release procedure as follows:-

- Remove fuel pump fuse

- Start car and allow engine to run until it dies (if non-runner crank engine for 60 seconds on starter)

Remove middle and rear undertrays

Get car as high as possible on axle stands (I jack one side using middle jacking point, then place stands at front and rear sub frame jacking points on one side, then do the same on the other side.

Release gear change cables from gearbox end

Release throttle cable from engine end

Remove r-clip from handbrake cable ‘horseshoe’ connector.

Remove front and rear bolts from sheer panel and remove exposing fuel tank

Remove off-side wheel

Remove off-side wheel arch liner

Pull back sound proofing on engine firewall to expose fuel filler and breather pipes

Loosen all jubilee clips holding pipes to tank

Pour 2 kettles of boiling water over rubber hoses so that they expand and become softer and then pull them off fuel tank connectors

Support fuel tank from underneath using jack(s) or something else suitable

At this point you can try to remove the pump connections as follows but my hands were far too big to make this possible! If you can’t just skip this step for now.

- Remove passenger seat

- Remove fuel pump access panel on shelf behind passenger seat

- Put hand through hole and disconnect fuel pipes by squeezing clips together and electrical connector by pulling tab on side a bit and pulling off

Undo the four fuel tank bolts

Slowly and carefully lower the tank whilst trying to feed the fuel pipes through the bulkhead a bit until you can get you hand up the side of the tank and release the fuel pipes and electrical connector as above

Then lower the tank and remove

Replacement is a reversal of removal but ensure electrical wires are not caught when you refit