Table of contents: Removal 🠇 Refitting 🠇
Removal
1. Disconnect the battery negative terminal (refer to "Disconnecting the battery").
2. For access to the fuel pick-up unit, fold the rear seat cushion forwards.
3. Using a screwdriver, carefully prise the plastic access cover from the floor to expose the fuel pump. Where two access covers are fitted, the pump is located under the righthand cover (viewed facing towards the front of the vehicle) (see illustration).
6.3. Remove the right-hand access cover to reveal the fuel pick-up unit
4. Mark the hoses for identification purposes, then slacken the feed and return hose retaining clips. Where crimped-type hose clips are fitted, cut the clips and discard them, replace them with standard worm-drive hose clips on refitting. On later models, quickrelease fittings may be fitted to the fuel hoses; these are released by depressing their metal collars with a small, flat-bladed screwdriver (see illustrations).
6.4a. Where quick-release type fittings are used, depress their metal centre collars to release them...
6.4b.... then pull the hoses away from the pick-up unit
5. Disconnect both hoses from the top of the pick-up unit and plug the hose ends.
6. Noting the alignment marks on the tank, pick-up unit and the locking ring, unscrew the ring and remove it from the tank (see illustration). This is best accomplished by using a screwdriver on the raised ribs of the locking ring. Carefully tap the screwdriver to turn the ring anti-clockwise until it can be unscrewed by hand.
6.6. Unscrew the locking ring...
7. Carefully lift the fuel pick-up assembly out of the fuel tank, taking great care not to damage the filter, or to spill fuel onto the interior of the vehicle. Recover the rubber sealing ring and discard it; a new one must be used on refitting (see illustration).
6.7. ... then lift out the pick-up unit and recover the rubber sealing ring
8. Note that the fuel pick-up assembly is only available as a complete assembly; no individual components are available separately.
Refitting
9. Ensure that the fuel pick-up filter is clean and free of debris. Fit the new sealing ring to the top of the fuel tank.
10. Carefully manoeuvre the pick-up unit into the fuel tank, aligning the mark noted on removal.
11. Refit the locking ring, tightening it until its mark is correctly aligned with the centre of the three lines on the fuel tank, as noted prior to removal (see illustration).
6.11. Tighten the sealing ring until its mark is aligned with the centre of the three ribs on the fuel tank (arrowed)
12. Reconnect the feed and return hoses, using the marks made on removal to ensure that they are correctly reconnected and (where necessary) securely tighten their retaining clips.
13. Reconnect the battery negative terminal and start the engine. Check the fuel feed and return hose unions for signs of leakage.
14. If all is well, refit the plastic access cover and fold back the rear seat cushion.