connected. If the hoses were originally
secured with crimped type clips, discard
these and use new worm drive clips.
2.0 litre DOHC models
17On these models the fuel pump is
mounted in the fuel tank, on the same
mounting as the fuel level sender unit(see
illustration).
18To remove the pump, first remove the fuel
tank.
19Unscrew the fuel pump/fuel level sender
unit by engaging two crossed screwdrivers in
the slots on either side of the unit mounting
flange. Recover the seal.
20Refitting is a reversal of removal. It is
necessary to fit a new seal.
1Run the fuel level as low as possible before
removing the tank.
2Disconnect the battery negative lead.
3Remove the tank filler cap, then syphon or
pump out the tank contents (there is no drain
plug). It may be necessary to disconnect the
fuel tank-to-fuel pump hose in order to fully
drain the tank. Store the petrol in a suitable
sealed container.
Saloon, Hatchback and Estate
models
4Working in the fuel filler recess, remove the
two screws on models up to 1987, or the
single screw on models from 1987, securing
the upper end of the fuel filler pipe to the body
panel.
5Chock the front wheels, then jack up the
rear of the vehicle and support on axle stands
(see “Jacking and Vehicle Support”).
6Unscrew the two securing bolts from the
left-hand tank flange, and on models from
1987, the single bolt from the right-hand tank
flange.7Support the tank, then remove the bolt from
the securing strap. Unhook the remaining end
of the strap from the underbody.
8Lower the tank sufficiently to disconnect
the two wiring plugs from the fuel level sender
(pump) unit (see illustration).
9Identify the fuel hose locations for use when
refitting, then disconnect the hoses from the
sender unit and plug them.
10Withdraw the fuel tank from under the
vehicle.
11The fuel filler and ventilation pipes can be
removed from the tank by loosening the
securing clips.
12If the tank is contaminated with sediment
or water, swill it out with clean petrol. If the
tank has a leak, or is damaged, it should be
repaired by a specialist, or alternatively
renewed. Do not under any circumstances
attempt to solder or weld a fuel tank.
13Refitting is a reversal of removal, but
ensure that the ventilation pipe is correctly
positioned in its groove in the tank, and is not
trapped between the tank and the vehicle
underbody. Ensure that the fuel hoses and the
fuel filler and ventilation pipes are correctly
connected, and if the hoses or pipes were
originally secured with crimped type clips,
discard these and use new worm drive clips.
P100 models
14Remove the cargo area (Chapter 12).
15Disconnect the wiring plug from the fuel
level sender unit, and release the wiring from
the clip on the fuel tank flange.
16Identify the fuel hose locations for use
when refitting, then disconnect the hoses
from the sender unit and plug them.
17Detach the fuel pipes from their clips on
the tank.
18Remove the five tank securing bolts, and
lift the tank from the chassis frame (see
illustration).
19Proceed as described in paragraphs 11
and 12.
20Commence refitting by loosening the
bolts securing the front tank mounting
brackets to the chassis frame.
21Lower the tank into position and loosely
refit the securing bolts. Tighten the three rear
securing bolts.
22Pull down on the front of the tank and
tighten the bolts securing the front tank
mounting brackets to the chassis frame whenthe brackets contact the insulating pads, then
tighten the front tank securing bolts.
23Further refitting is a reversal of removal,
but ensure that all hoses and pipes are
correctly connected, and if the hoses or pipes
were originally secured with crimped type
clips, discard these and use new worm drive
clips. Refit the cargo area.
Saloon, Hatchback and Estate
models
All models except 2.0 litre DOHC
1Remove the fuel tank.
2Unscrew the sender unit from the tank by
engaging two crossed screwdrivers in the
slots on either side of the sender unit
mounting flange. Recover the seal. Check the
condition of the gauze filter on the fuel pick-
up pipe, and renew it if there is any sign of
deterioration.
3Refitting is a reversal of removal, but fit a
new seal.
2.0 litre DOHC models
4On these models the sender unit is
combined with the fuel pump. See Section 8
for unit removal and refitting.
P100 models
5Remove the cargo area (Chapter 12).
6Disconnect the wiring plug from the sender
unit.
7Identify the fuel hose locations, as an aid to
refitting, then disconnect the hoses from the
sender unit and plug them.
8Proceed as described in paragraph 2.
9Refitting is a reversal of removal, but fit a
new seal, and ensure that the fuel hoses are
correctly connected. If the hoses were
originally secured with crimped type clips,
discard these and use new worm drive clips.
Refit the cargo area.
10Fuel level sender unit -
removal and refitting
9Fuel tank - removal and refitting
Fuel and exhaust systems - carburettor 4A•7
4A
9.8 Fuel level sender unit connections -
Saloon, Hatchback and Estate models
A Wiring plugs
B Fuel outlet pipeC Fuel inlet pipe
9.18 Fuel tank securing bolts (arrowed) -
P100 models
8.17 Combined fuel pump/fuel level sender
unit - 1.6/1.8 litre (R6A) CVH models
A Fuel pumpB Fuel level sender
unit
Caution: Refer to the
precautions in Section 1 before
proceeding.
Caution: Refer to the
precautions in Section 1 before
proceeding. A new seal must
be used when refitting the
sender unit.
