Fuel System tank removal

Hacksawbob Petrol tank removal 1.9 DG disconnect earth(s) from batterie(s) You CAN do this without jacking the van up but it makes refitting much harder. jack both sides and support on axel stands. empty fuel from main tank disconect fuel supply to engine (the side with the filter) disconnect return fuel line from engine , on the other left hand side (didn't know that was there did you!) disconnect fuel expansion tank (wheel arches) BOTTOM connectors (not top) both sides prop the tank with a trolley jack, I used a borrowed "diamond" shaped emergency jack wich worked better in the confined space under the van. undo the 13m bolts holding the metal tank straps remove the tank straps you may need to bend up the inner corners from the "hooks" at the rear of the starps if you dont have the van jacked as they wont come off other wise slowly lower the tank. half way down take a look above the tank and try and help out the connecting grommets that are one the the front/top of the tanks remove the rubber from the tank and leave the white plastic hose connectors in situ if pos There are three. Also ease out the main filler pipe from the tank, its only held in there with pressure from a rubber seal. (interference fit) Drop the tank to the ground slowly checking for snags. try remove any other connectors you can see, the ones from the expansion tanks should have pulled through. there is an electrical connector to the fuel tank sender (level) but this had enough slack to reach the ground. remove this too once the tank is down, it just pulls off remove the tank from under the van

do what ever you wanted to do with the tank out. (i.e. change the hand brake cable...)

your tank will be rusty if you want to treat it be aware that it is still full of petrol fumes so power tools may not be a good idea. sand down the outside rot by hand and treat with Eastmans rust encapsulator or similar, re-fitting is very awkward I attached the breather tubes to the rubber grommets on top of the main tank but not to the expansion tanks. you need to do this after the rear end on the tank is up and engaged and the the tank straps are in you may wish that you had jacked the van up at this point to give you some room. Also you will need to get that filler pipe back in I put in the tank end first and then forced the top end back into the petrol cap rubber , not ideal but I couldn't see how else to do it.